Suzuki JB627 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD

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Suzuki JB627 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD

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Suzuki JB627 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD

Language : English
Pages : 1701
Downloadable : Yes
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DESCRIPTION:

Suzuki JB627 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD

• This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
• VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
• VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10).
  Applicable model:
  GRAND VITARA (JB627) vehicles
• The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
• This manual should be kept in a handy place for ready reference of the service work.
• Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
• When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
• All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
• Therefore, note that illustrations may differ from the vehicle being actually serviced.
• The right is reserved to make changes at any time without notice.

TABLE OF CONTENTS:

Suzuki JB627 Grand Vitara Service Manual (Vol 1&2) – PDF DOWNLOAD

Top………………………………………………………………………………………………………………………………………………………………………………………………………….. 0
Manual List…………………………………………………………………………………………………………………………………………………………………………………………………… 0
IMPORTANT…………………………………………………………………………………………………………………………………………………………………………………………………….. 1
FOREWORD……………………………………………………………………………………………………………………………………………………………………………………………………… 3
TABLE OF CONTENTS……………………………………………………………………………………………………………………………………………………………………………………………… 5
Precautions…………………………………………………………………………………………………………………………………………………………………………………………………… 7
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 8
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System…………………………………………………………………………………………………………………………… 8
General Precautions…………………………………………………………………………………………………………………………………………………………………………………. 11
Precaution in Servicing Full-Time 4WD Vehicle………………………………………………………………………………………………………………………………………………………….. 14
Precautions for Catalytic Converter…………………………………………………………………………………………………………………………………………………………………… 15
Precaution for CAN Communication System……………………………………………………………………………………………………………………………………………………………….. 16
Precautions for Electrical Circuit Service…………………………………………………………………………………………………………………………………………………………….. 16
Precautions for Installing Mobile Communication Equipment……………………………………………………………………………………………………………………………………………….. 18
Air Bag Warning…………………………………………………………………………………………………………………………………………………………………………………….. 18
Discharge Headlight Warning………………………………………………………………………………………………………………………………………………………………………….. 18
A/C System Caution………………………………………………………………………………………………………………………………………………………………………………….. 19
Fastener Caution……………………………………………………………………………………………………………………………………………………………………………………. 19
Suspension Caution………………………………………………………………………………………………………………………………………………………………………………….. 19
Wheels and Tires Caution…………………………………………………………………………………………………………………………………………………………………………….. 19
Brakes Caution and Note……………………………………………………………………………………………………………………………………………………………………………… 20
Differential Gear Oil Note…………………………………………………………………………………………………………………………………………………………………………… 20
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 20
Electrical Circuit Inspection Procedure……………………………………………………………………………………………………………………………………………………………….. 20
Intermittent and Poor Connection Inspection……………………………………………………………………………………………………………………………………………………………. 22
General Information……………………………………………………………………………………………………………………………………………………………………………………………. 25
General Information………………………………………………………………………………………………………………………………………………………………………………………… 26
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 26
Abbreviations………………………………………………………………………………………………………………………………………………………………………………………. 26
Symbols……………………………………………………………………………………………………………………………………………………………………………………………. 27
Wire Color Symbols………………………………………………………………………………………………………………………………………………………………………………….. 28
Fastener Information………………………………………………………………………………………………………………………………………………………………………………… 28
Vehicle Lifting Points………………………………………………………………………………………………………………………………………………………………………………. 30
Vehicle Identification Number………………………………………………………………………………………………………………………………………………………………………… 32
Engine Identification Number…………………………………………………………………………………………………………………………………………………………………………. 32
Transmission Identification Number……………………………………………………………………………………………………………………………………………………………………. 32
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 33
Warning, Caution and Information Label Location………………………………………………………………………………………………………………………………………………………… 33
Maintenance and Lubrication…………………………………………………………………………………………………………………………………………………………………………………. 35
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 35
Precautions for Maintenance and Lubrication……………………………………………………………………………………………………………………………………………………………. 35
Scheduled Maintenance…………………………………………………………………………………………………………………………………………………………………………………… 35
Maintenance Schedule under Normal Driving Conditions……………………………………………………………………………………………………………………………………………………. 35
Maintenance Recommended under Severe Driving Conditions…………………………………………………………………………………………………………………………………………………. 36
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 37
Engine Accessory Drive Belt Inspection………………………………………………………………………………………………………………………………………………………………… 37
Engine Accessory Drive Belt Replacement……………………………………………………………………………………………………………………………………………………………….. 37
Valve Lash (Clearance) Inspection…………………………………………………………………………………………………………………………………………………………………….. 38
Engine Oil and Filter Change…………………………………………………………………………………………………………………………………………………………………………. 38
Engine Coolant Change……………………………………………………………………………………………………………………………………………………………………………….. 39
Exhaust system Inspection……………………………………………………………………………………………………………………………………………………………………………. 39
Spark Plugs Replacement……………………………………………………………………………………………………………………………………………………………………………… 39
Air Cleaner Filter Inspection………………………………………………………………………………………………………………………………………………………………………… 39
Air Cleaner Filter Replacement……………………………………………………………………………………………………………………………………………………………………….. 39
Fuel Lines and Connections Inspection…………………………………………………………………………………………………………………………………………………………………. 40
Fuel Filter Replacement……………………………………………………………………………………………………………………………………………………………………………… 40
Fuel Tank Inspection………………………………………………………………………………………………………………………………………………………………………………… 40
Crankcase Ventilation Hoses and Connections Inspection (Vehicle without A/F Sensor)………………………………………………………………………………………………………………………… 40
PCV Valve Inspection………………………………………………………………………………………………………………………………………………………………………………… 40
Fuel Evaporative Emission Control System Inspection…………………………………………………………………………………………………………………………………………………….. 40
Brake Discs and Pads Inspection………………………………………………………………………………………………………………………………………………………………………. 40
Brake Drums and Shoes Inspection……………………………………………………………………………………………………………………………………………………………………… 40
Brake Hoses and Pipes Inspection……………………………………………………………………………………………………………………………………………………………………… 41
Brake Fluid Change………………………………………………………………………………………………………………………………………………………………………………….. 41
Parking Brake Lever and Cable Inspection………………………………………………………………………………………………………………………………………………………………. 41
Clutch Fluid Inspection……………………………………………………………………………………………………………………………………………………………………………… 41
Tire / Wheel Inspection and Rotation………………………………………………………………………………………………………………………………………………………………….. 42
Wheel Discs Inspection………………………………………………………………………………………………………………………………………………………………………………. 42
Wheel Bearing Inspection…………………………………………………………………………………………………………………………………………………………………………….. 42
Suspension System Inspection…………………………………………………………………………………………………………………………………………………………………………. 42
Steering System Inspection…………………………………………………………………………………………………………………………………………………………………………… 43
Propeller Shafts and Drive Shafts Inspection…………………………………………………………………………………………………………………………………………………………… 44
Manual Transmission Oil Inspection……………………………………………………………………………………………………………………………………………………………………. 44
Manual Transmission Oil Change……………………………………………………………………………………………………………………………………………………………………….. 44
Automatic Transmission Fluid Inspection……………………………………………………………………………………………………………………………………………………………….. 44
Automatic Transmission Fluid Change…………………………………………………………………………………………………………………………………………………………………… 44
Automatic Transmission Fluid Cooler Hose Inspection…………………………………………………………………………………………………………………………………………………….. 45
Transfer Oil Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………………………. 45
Differential Oil Inspection………………………………………………………………………………………………………………………………………………………………………….. 45
Transfer (If Equipped) or Differential Oil Change………………………………………………………………………………………………………………………………………………………. 45
Power Steering (P/S) System Inspection………………………………………………………………………………………………………………………………………………………………… 45
All Hinges, Latches and Locks Inspection………………………………………………………………………………………………………………………………………………………………. 46
HVAC Air Filter Inspection (If Equipped)………………………………………………………………………………………………………………………………………………………………. 46
HVAC Air Filter Replacement (If Equipped)……………………………………………………………………………………………………………………………………………………………… 46
Final Inspection for Maintenance Service………………………………………………………………………………………………………………………………………………………………. 46
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 48
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 48
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 48
Recommended Fluids and Lubricants…………………………………………………………………………………………………………………………………………………………………….. 48
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 48
Engine……………………………………………………………………………………………………………………………………………………………………………………………………….. 49
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 55
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 55
Precautions for Engine………………………………………………………………………………………………………………………………………………………………………………. 55
Engine General Information and Diagnosis……………………………………………………………………………………………………………………………………………………………………… 56
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 56
Precautions on Engine Service………………………………………………………………………………………………………………………………………………………………………… 56
Precautions in Diagnosing Trouble…………………………………………………………………………………………………………………………………………………………………….. 56
Precautions for DTC Troubleshooting…………………………………………………………………………………………………………………………………………………………………… 57
Precautions of ECM Circuit Inspection…………………………………………………………………………………………………………………………………………………………………. 57
Precautions of Electric Throttle Body System Calibration………………………………………………………………………………………………………………………………………………… 57
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 58
Statement of Cleanliness and Care…………………………………………………………………………………………………………………………………………………………………….. 58
Engine Diagnosis General Description………………………………………………………………………………………………………………………………………………………………….. 58
On-Board Diagnostic System Description………………………………………………………………………………………………………………………………………………………………… 58
Engine and Emission Control System Description…………………………………………………………………………………………………………………………………………………………. 61
Air Intake System Description………………………………………………………………………………………………………………………………………………………………………… 62
Description of Electric Throttle Body System…………………………………………………………………………………………………………………………………………………………… 62
Description of Electric Throttle Body System Calibration………………………………………………………………………………………………………………………………………………… 63
A/F Sensor Description………………………………………………………………………………………………………………………………………………………………………………. 64
CAN Communication System Description………………………………………………………………………………………………………………………………………………………………….. 65
Electronic Control System Description…………………………………………………………………………………………………………………………………………………………………. 68
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 79
Engine and Emission Control System Diagram…………………………………………………………………………………………………………………………………………………………….. 79
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 80
Engine and Emission Control System Check………………………………………………………………………………………………………………………………………………………………. 80
Visual Inspection…………………………………………………………………………………………………………………………………………………………………………………… 84
Engine Basic Check………………………………………………………………………………………………………………………………………………………………………………….. 85
Malfunction Indicator Lamp (MIL) Check………………………………………………………………………………………………………………………………………………………………… 86
DTC Table………………………………………………………………………………………………………………………………………………………………………………………….. 86
For A/T System (Only OBD Generic Scan Tool Is Displayed on the Following DTC(s) at the Same Time)……………………………………………………………………………………………………………. 95
DTC Check………………………………………………………………………………………………………………………………………………………………………………………….. 96
DTC Clearance………………………………………………………………………………………………………………………………………………………………………………………. 97
Fail-Safe Table…………………………………………………………………………………………………………………………………………………………………………………….. 97
Scan Tool Data……………………………………………………………………………………………………………………………………………………………………………………… 100
Engine Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………………….. 108
Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)……………………………………………………………………………………………….. 115
Malfunction Indicator Lamp Remains ON after Engine Starts……………………………………………………………………………………………………………………………………………….. 117
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1, Bank-1)………………………………………………………………………………………………………………………………. 118
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2, Bank-1)………………………………………………………………………………………………………………………………. 122
DTC P0051 / P0052: HO2S Heater Control Circuit Low / High (Sensor-1, Bank-2)………………………………………………………………………………………………………………………………. 124
DTC P0057 / P0058: HO2S Heater Control Circuit Low / High (Sensor-2, Bank-2)………………………………………………………………………………………………………………………………. 128
DTC P0101: Mass Air Flow Circuit Range / Performance……………………………………………………………………………………………………………………………………………………. 131
DTC P0102 / P0103: Mass Air Flow Circuit Low / High Input……………………………………………………………………………………………………………………………………………….. 133
DTC P0107 / P0108: Manifold Absolute Pressure Sensor Circuit Low / High Input……………………………………………………………………………………………………………………………… 135
DTC P0111: Intake Air Temperature Sensor Circuit Performance…………………………………………………………………………………………………………………………………………….. 137
DTC P0112 / P0113: Intake Air Temperature Sensor Circuit Low / High Input…………………………………………………………………………………………………………………………………. 138
DTC P0116: Engine Coolant Temperature Circuit Range / Performance………………………………………………………………………………………………………………………………………… 140
DTC P0117 / P0118: Engine Coolant Temperature Circuit Low / High Input……………………………………………………………………………………………………………………………………. 142
DTC P0122 / P0123: Throttle Position Sensor (Main) Circuit Low / High Input……………………………………………………………………………………………………………………………….. 144
DTC P0133 / P2A00: O2 Sensor Circuit Slow Response / Performance (Sensor-1, Bank-1)………………………………………………………………………………………………………………………… 146
DTC P0134: O2 Sensor Circuit No Activity (Sensor-1, Bank-1)……………………………………………………………………………………………………………………………………………… 148
DTC P0137 / P0138: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-2, Bank-1)…………………………………………………………………………………………………………………………. 150
DTC P0140: O2 Sensor Circuit No Activity Detected (Sensor-2, Bank-1)……………………………………………………………………………………………………………………………………… 152
DTC P0153 / P2A03: O2 Sensor Circuit Slow Response / Performance (Sensor-1, Bank-2)………………………………………………………………………………………………………………………… 154
DTC P0154: O2 Sensor Circuit No Activity (Sensor-1, Bank-2)……………………………………………………………………………………………………………………………………………… 156
DTC P0157 / P0158: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-2, Bank-2)…………………………………………………………………………………………………………………………. 158
DTC P0160: O2 Sensor Circuit No Activity Detected (Sensor-2, Bank-2)……………………………………………………………………………………………………………………………………… 160
DTC P0171 / P0172: System Too Lean / Too Rich (Sensor-1, Bank-1)…………………………………………………………………………………………………………………………………………. 162
DTC P0174 / P0175: System Too Lean / Too Rich (Sensor-1, Bank-2)…………………………………………………………………………………………………………………………………………. 165
DTC P0222 / P0223: Throttle Position Sensor (Sub) Circuit Low/High……………………………………………………………………………………………………………………………………….. 168
DTC P0300 / P0301 / P0302 / P0303 / P0304 / P0305 / P0306: Misfire Detected……………………………………………………………………………………………………………………………….. 170
DTC P0327 / P0328: Knock Sensor Circuit Low / High……………………………………………………………………………………………………………………………………………………… 172
DTC P0335: Crankshaft Position Sensor Circuit………………………………………………………………………………………………………………………………………………………….. 174
DTC P0336: Crankshaft Position Sensor Circuit Range / Performance………………………………………………………………………………………………………………………………………… 176
DTC P0340: Camshaft Position Sensor Circuit……………………………………………………………………………………………………………………………………………………………. 177
DTC P0341: Camshaft Position Sensor Circuit Range / Performance………………………………………………………………………………………………………………………………………….. 179
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected………………………………………………………………………………………………………………… 180
DTC P0403: Exhaust Gas Recirculation Control Circuit……………………………………………………………………………………………………………………………………………………. 182
DTC P0420 / P0430: Catalyst System Efficiency Below Threshold (Bank-1 / -2)……………………………………………………………………………………………………………………………….. 184
DTC P0444 / P0445: EVAP Emission System Purge Control Valve Circuit Open / Shorted…………………………………………………………………………………………………………………………. 186
DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High…………………………………………………………………………………………………………………………………………………. 188
DTC P0480 / P0481 / P0482: Fan 1 / Fan 2 / Fan 3 Control Circuit…………………………………………………………………………………………………………………………………………. 190
DTC P0500: Vehicle Speed Sensor………………………………………………………………………………………………………………………………………………………………………. 192
DTC P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit Low / High…………………………………………………………………………………………………………………………………….. 193
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance………………………………………………………………………… 195
DTC P0616 / P0617: Starter Relay Circuit Low / High…………………………………………………………………………………………………………………………………………………….. 196
DTC P0645: A/C Clutch Relay Control Circuit……………………………………………………………………………………………………………………………………………………………. 198
DTC P0661 / P0662: Intake Manifold Tuning Valve Control Circuit Low / High………………………………………………………………………………………………………………………………… 200
DTC P1107 / P1108: Manifold Absolute Pressure Sensor Rationality Check – Low / High………………………………………………………………………………………………………………………… 202
DTC P1510: ECM Back-Up Power Supply Malfunction………………………………………………………………………………………………………………………………………………………… 204
DTC P1603: TCM Trouble Code Detected………………………………………………………………………………………………………………………………………………………………….. 205
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance……………………………………………………………………………………………………………………………………. 206
DTC P2102: Throttle Actuator Control Motor Circuit Low………………………………………………………………………………………………………………………………………………….. 208
DTC P2103: Throttle Actuator Control Motor Circuit High…………………………………………………………………………………………………………………………………………………. 210
DTC P2108: Throttle Actuator Control Module Performance…………………………………………………………………………………………………………………………………………………. 211
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance……………………………………………………………………………………………………………………………………. 212
DTC P2122 / P2123: Pedal Position Sensor (Main) Circuit Low / High……………………………………………………………………………………………………………………………………….. 213
DTC P2127 / P2128: Pedal Position Sensor (Sub) Circuit Low / High………………………………………………………………………………………………………………………………………… 215
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correction………………………………………………………………………………………………………………………………………. 217
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correction…………………………………………………………………………………………………………………………………………. 219
DTC P2195 / P2196: O2 Sensor Signal Stuck Lean / Stuck Rich (Sensor-1, Bank-1)…………………………………………………………………………………………………………………………….. 221
DTC P2197 / P2198: O2 Sensor Signal Stuck Lean / Stuck Rich (Sensor-1, Bank-2)…………………………………………………………………………………………………………………………….. 224
DTC P2227/ P2228 / P2229: Barometric Pressure Circuit Malfunction………………………………………………………………………………………………………………………………………… 226
DTC P2237: O2 Sensor Positive Current Control Circuit / Open (Sensor-1, Bank-1)……………………………………………………………………………………………………………………………. 227
DTC P2238 / P2239: O2 Sensor Positive Current Control Circuit Low / High (Sensor-1, Bank-1)…………………………………………………………………………………………………………………. 229
DTC P2240: O2 Sensor Positive Current Control Circuit / Open (Sensor-1, Bank-2)……………………………………………………………………………………………………………………………. 231
DTC P2241 / P2242: O2 Sensor Positive Current Control Circuit Low / High (Sensor-1, Bank-2)…………………………………………………………………………………………………………………. 233
DTC P2252 / P2253: O2 Sensor Negative Current Control Circuit Low/High (Sensor-1, Bank-1)…………………………………………………………………………………………………………………… 235
DTC P2255 / P2256: O2 Sensor Negative Current Control Circuit Low/High (Sensor-1, Bank-2)…………………………………………………………………………………………………………………… 237
DTC P2627 / P2628: O2 Sensor Pumping Current Trim Circuit Low / High (Sensor-1, Bank-1)…………………………………………………………………………………………………………………….. 239
DTC P2630 / P2631: O2 Sensor Pumping Current Trim Circuit Low / High (Sensor-1, Bank-2)…………………………………………………………………………………………………………………….. 241
DTC P2A01: O2 Sensor Circuit Performance (Sensor-2, Bank-1)……………………………………………………………………………………………………………………………………………… 243
DTC P2A04: O2 Sensor Circuit Performance (Sensor-2, Bank-2)……………………………………………………………………………………………………………………………………………… 245
DTC U0073: Control Module Communication Bus Off………………………………………………………………………………………………………………………………………………………… 247
DTC U0101: Lost Communication with TCM………………………………………………………………………………………………………………………………………………………………… 251
DTC U0121: Lost Communication with ABS Control Module…………………………………………………………………………………………………………………………………………………… 255
DTC U0140: Lost Communication with Body Control Module………………………………………………………………………………………………………………………………………………….. 258
Inspection of ECM and Its Circuits……………………………………………………………………………………………………………………………………………………………………. 262
ECM Power and Ground Circuit Check……………………………………………………………………………………………………………………………………………………………………. 285
Fuel Injector Circuit Check………………………………………………………………………………………………………………………………………………………………………….. 288
Fuel Pump and Its Circuit Check………………………………………………………………………………………………………………………………………………………………………. 290
Fuel Pressure Check…………………………………………………………………………………………………………………………………………………………………………………. 292
A/C System Circuits Check……………………………………………………………………………………………………………………………………………………………………………. 294
Electric Load Signal Circuit Check……………………………………………………………………………………………………………………………………………………………………. 297
Radiator Cooling Fan Low Speed Control System Check…………………………………………………………………………………………………………………………………………………….. 299
Radiator Cooling Fan High Speed Control System Check……………………………………………………………………………………………………………………………………………………. 302
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 304
Idle Speed and IAC Throttle Valve Opening Inspection……………………………………………………………………………………………………………………………………………………. 304
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 305
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 305
Aux. Emission Control Devices……………………………………………………………………………………………………………………………………………………………………………….. 306
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 306
PCV System Location…………………………………………………………………………………………………………………………………………………………………………………. 306
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 307
EGR System Inspection……………………………………………………………………………………………………………………………………………………………………………….. 307
EVAP Canister Purge System Inspection…………………………………………………………………………………………………………………………………………………………………. 307
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 308
EVAP Canister Purge Valve and Its Circuit……………………………………………………………………………………………………………………………………………………………… 308
EVAP Canister Purge Valve Inspection………………………………………………………………………………………………………………………………………………………………….. 309
EVAP Canister Removal and Installation………………………………………………………………………………………………………………………………………………………………… 310
EVAP Canister Inspection…………………………………………………………………………………………………………………………………………………………………………….. 310
Vacuum Passage Inspection……………………………………………………………………………………………………………………………………………………………………………. 310
PCV Hose Inspection…………………………………………………………………………………………………………………………………………………………………………………. 310
PCV Valve Removal and Installation……………………………………………………………………………………………………………………………………………………………………. 311
PCV Valve Inspection………………………………………………………………………………………………………………………………………………………………………………… 311
EGR Valve Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………………. 311
EGR Valve Assembly Inspection………………………………………………………………………………………………………………………………………………………………………… 312
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 313
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 313
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 313
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 313
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 313
Engine Electrical Devices…………………………………………………………………………………………………………………………………………………………………………………… 314
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 314
Engine Control Module (ECM) Removal and Installation……………………………………………………………………………………………………………………………………………………. 314
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection………………………………………………………………………………………………………………………….. 315
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation……………………………………………………………………………………………………………………….. 316
Electric Throttle Body Assembly On-Vehicle Inspection…………………………………………………………………………………………………………………………………………………… 316
Electric Throttle Body System Calibration……………………………………………………………………………………………………………………………………………………………… 318
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection……………………………………………………………………………………………………………………………………. 319
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation…………………………………………………………………………………………………………………………………. 319
Accelerator Pedal Position (APP) Sensor Assembly Inspection……………………………………………………………………………………………………………………………………………… 320
Engine Coolant Temperature (ECT) Sensor Removal and Installation…………………………………………………………………………………………………………………………………………. 320
Engine Coolant Temperature (ECT) Sensor Inspection……………………………………………………………………………………………………………………………………………………… 321
Manifold Absolute Pressure (MAP) Sensor Removal and Installation…………………………………………………………………………………………………………………………………………. 321
Manifold Absolute Pressure (MAP) Sensor Inspection……………………………………………………………………………………………………………………………………………………… 322
Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection………………………………………………………………………………………………………………………………………………………. 322
Heated Oxygen Sensor (HO2S-2) Heater On- Vehicle Inspection……………………………………………………………………………………………………………………………………………… 323
Air Fuel Ratio (A/F) Sensor (Sensor-1) Removal and Installation………………………………………………………………………………………………………………………………………….. 324
Heated Oxygen Sensor (Sensor-2) Removal and Installation………………………………………………………………………………………………………………………………………………… 325
Camshaft Position (CMP) Sensor Removal and Installation…………………………………………………………………………………………………………………………………………………. 325
Crankshaft Position (CKP) Sensor Removal and Installation……………………………………………………………………………………………………………………………………………….. 326
Camshaft Position (CMP) Sensor and Crankshaft Position (CKP) Sensor Inspection…………………………………………………………………………………………………………………………….. 326
Knock Sensor Removal and Installation…………………………………………………………………………………………………………………………………………………………………. 327
Engine and Emission Control System Relay Inspection…………………………………………………………………………………………………………………………………………………….. 327
IMT Vacuum Tank Assembly Inspection…………………………………………………………………………………………………………………………………………………………………… 328
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 330
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 330
Engine Mechanical………………………………………………………………………………………………………………………………………………………………………………………….. 331
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 331
Engine General Information…………………………………………………………………………………………………………………………………………………………………………… 331
Air Cleaner Filter Introduction………………………………………………………………………………………………………………………………………………………………………. 331
IMT (Intake Manifold Tuning) System…………………………………………………………………………………………………………………………………………………………………… 331
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 333
Compression Check…………………………………………………………………………………………………………………………………………………………………………………… 333
Engine Vacuum Check…………………………………………………………………………………………………………………………………………………………………………………. 334
Valve Lash (Clearance) Inspection…………………………………………………………………………………………………………………………………………………………………….. 334
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 337
Air Intake System Components…………………………………………………………………………………………………………………………………………………………………………. 337
Air Cleaner Filter Removal and Installation……………………………………………………………………………………………………………………………………………………………. 338
Air Cleaner Filter Inspection and Cleaning…………………………………………………………………………………………………………………………………………………………….. 338
Intake Collector and Intake Manifold Components………………………………………………………………………………………………………………………………………………………… 339
Electric Throttle Body Assembly On-Vehicle Inspection…………………………………………………………………………………………………………………………………………………… 340
Electric Throttle Body Assembly Removal and Installation………………………………………………………………………………………………………………………………………………… 340
IMT (Intake Manifold Tuning) Valve Removal and Installation……………………………………………………………………………………………………………………………………………… 341
IMT (Intake Manifold Tuning) Valve Inspection………………………………………………………………………………………………………………………………………………………….. 341
Intake Collector and Intake Manifold Removal and Installation……………………………………………………………………………………………………………………………………………. 342
Cylinder Head Covers Removal and Installation………………………………………………………………………………………………………………………………………………………….. 344
Engine Mounting Components…………………………………………………………………………………………………………………………………………………………………………… 346
Engine Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………………. 347
Timing Chain Cover Components………………………………………………………………………………………………………………………………………………………………………… 350
Engine Block Heater (If Equipped) Removal and Installation………………………………………………………………………………………………………………………………………………. 350
Engine Block Heater (If Equipped) Inspection…………………………………………………………………………………………………………………………………………………………… 351
Timing Chain Cover Removal and Installation……………………………………………………………………………………………………………………………………………………………. 351
Timing Chain Cover Inspection………………………………………………………………………………………………………………………………………………………………………… 353
LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Components…………………………………………………………………………………………………………………………………………… 353
LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Removal and Installation………………………………………………………………………………………………………………………………. 354
LH (No.1) Bank 2nd Timing Chain and Chain Tensioner Inspection…………………………………………………………………………………………………………………………………………… 358
1st Timing Chain and Chain Tensioner Components………………………………………………………………………………………………………………………………………………………… 359
1st Timing Chain and Chain Tensioner Removal and Installation……………………………………………………………………………………………………………………………………………. 360
1st Timing Chain and Chain Tensioner Inspection………………………………………………………………………………………………………………………………………………………… 364
RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Components…………………………………………………………………………………………………………………………………………… 365
RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Removal and Installation………………………………………………………………………………………………………………………………. 366
RH (No.2) Bank 2nd Timing Chain and Chain Tensioner Inspection…………………………………………………………………………………………………………………………………………… 368
Camshafts, Tappets and Shims Components……………………………………………………………………………………………………………………………………………………………….. 369
Camshafts, Tappets and Shims Removal and Installation…………………………………………………………………………………………………………………………………………………… 370
Camshafts and Camshaft Housings Inspection…………………………………………………………………………………………………………………………………………………………….. 372
Tappets and Shims Inspection…………………………………………………………………………………………………………………………………………………………………………. 373
Valves and Cylinder Heads Components………………………………………………………………………………………………………………………………………………………………….. 374
Valves and Cylinder Heads Removal and Installation……………………………………………………………………………………………………………………………………………………… 375
Valves and Cylinder Heads Disassembly and Reassembly……………………………………………………………………………………………………………………………………………………. 377
Valves and Valve Guides Inspection……………………………………………………………………………………………………………………………………………………………………. 379
Cylinder Head Inspection…………………………………………………………………………………………………………………………………………………………………………….. 381
Valve Springs Inspection…………………………………………………………………………………………………………………………………………………………………………….. 382
Pistons, Piston Rings, Connecting Rods and Cylinders Components………………………………………………………………………………………………………………………………………….. 383
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation……………………………………………………………………………………………………………………………… 384
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly……………………………………………………………………………………………………………………………. 385
Cylinders, Pistons and Piston Rings Inspection…………………………………………………………………………………………………………………………………………………………. 387
Piston Pins and Connecting Rods Inspection…………………………………………………………………………………………………………………………………………………………….. 389
Crank Pins and Connecting Rod Bearings Inspection………………………………………………………………………………………………………………………………………………………. 390
Main Bearings, Crankshaft and Cylinder Block Components…………………………………………………………………………………………………………………………………………………. 394
Main Bearings, Crankshaft and Cylinder Block Removal and Installation…………………………………………………………………………………………………………………………………….. 395
Crankshaft Inspection……………………………………………………………………………………………………………………………………………………………………………….. 398
Main Bearings Inspection…………………………………………………………………………………………………………………………………………………………………………….. 399
Rear Oil Seal and Flywheel Inspection…………………………………………………………………………………………………………………………………………………………………. 403
Cylinder Block Inspection……………………………………………………………………………………………………………………………………………………………………………. 403
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 404
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 404
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 405
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 405
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 405
Engine Lubrication System…………………………………………………………………………………………………………………………………………………………………………………… 408
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 408
Engine Lubrication………………………………………………………………………………………………………………………………………………………………………………….. 408
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 409
Oil Pressure Check………………………………………………………………………………………………………………………………………………………………………………….. 409
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 410
Oil Pan and Oil Pump Strainer Components………………………………………………………………………………………………………………………………………………………………. 410
Oil Pan and Oil Pump Strainer Removal and Installation………………………………………………………………………………………………………………………………………………….. 411
Oil Pan and Oil Pump Strainer Cleaning………………………………………………………………………………………………………………………………………………………………… 413
Oil Pump and Oil Pump Chain Components………………………………………………………………………………………………………………………………………………………………… 413
Oil Pump and Oil Pump Chain Removal and Installation……………………………………………………………………………………………………………………………………………………. 414
Oil Pump and Oil Pump Chain Inspection………………………………………………………………………………………………………………………………………………………………… 415
Oil Pump Disassembly and Reassembly…………………………………………………………………………………………………………………………………………………………………… 415
Oil Pump Inspection…………………………………………………………………………………………………………………………………………………………………………………. 416
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 417
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 417
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 417
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 417
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 417
Engine Cooling System………………………………………………………………………………………………………………………………………………………………………………………. 418
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 418
Cooling System Description…………………………………………………………………………………………………………………………………………………………………………… 418
Coolant Description…………………………………………………………………………………………………………………………………………………………………………………. 418
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 419
Coolant Circulation…………………………………………………………………………………………………………………………………………………………………………………. 419
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 420
Engine Cooling Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………………… 420
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 421
Cooling System Components……………………………………………………………………………………………………………………………………………………………………………. 421
Coolant Level Check…………………………………………………………………………………………………………………………………………………………………………………. 422
Engine Cooling System Inspection and Cleaning………………………………………………………………………………………………………………………………………………………….. 422
Cooling System Draining……………………………………………………………………………………………………………………………………………………………………………… 423
Cooling System Flush and Refill………………………………………………………………………………………………………………………………………………………………………. 423
Cooling Water Pipes or Hoses Removal and Installation…………………………………………………………………………………………………………………………………………………… 423
Thermostat Removal and Installation…………………………………………………………………………………………………………………………………………………………………… 424
Thermostat Inspection……………………………………………………………………………………………………………………………………………………………………………….. 424
Radiator Cooling Fan Motor On-Vehicle Inspection……………………………………………………………………………………………………………………………………………………….. 425
Radiator Cooling Fan Relay Inspection…………………………………………………………………………………………………………………………………………………………………. 425
Radiator Cooling Fan Assembly Removal and Installation………………………………………………………………………………………………………………………………………………….. 426
Radiator On-Vehicle Inspection and Cleaning……………………………………………………………………………………………………………………………………………………………. 426
Radiator Removal and Installation…………………………………………………………………………………………………………………………………………………………………….. 426
Water Pump Removal and Installation…………………………………………………………………………………………………………………………………………………………………… 427
Water Pump Inspection……………………………………………………………………………………………………………………………………………………………………………….. 427
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 428
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 428
Fuel System……………………………………………………………………………………………………………………………………………………………………………………………….. 429
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 429
Precautions on Fuel System Service……………………………………………………………………………………………………………………………………………………………………. 429
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 429
Fuel System Description……………………………………………………………………………………………………………………………………………………………………………… 429
Fuel Delivery System Description……………………………………………………………………………………………………………………………………………………………………… 429
Fuel Pump Description……………………………………………………………………………………………………………………………………………………………………………….. 430
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 430
Fuel Delivery System Diagram…………………………………………………………………………………………………………………………………………………………………………. 430
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 431
Fuel Pressure Inspection…………………………………………………………………………………………………………………………………………………………………………….. 431
Fuel Cut Operation Inspection………………………………………………………………………………………………………………………………………………………………………… 432
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 433
Fuel System Components………………………………………………………………………………………………………………………………………………………………………………. 433
Fuel Hose Disconnecting and Reconnecting………………………………………………………………………………………………………………………………………………………………. 434
Fuel Pressure Relief Procedure……………………………………………………………………………………………………………………………………………………………………….. 436
Fuel Leakage Check Procedure…………………………………………………………………………………………………………………………………………………………………………. 436
Fuel Lines On-Vehicle Inspection……………………………………………………………………………………………………………………………………………………………………… 436
Fuel Pipe Removal and Installation……………………………………………………………………………………………………………………………………………………………………. 437
Fuel Injector On-Vehicle Inspection…………………………………………………………………………………………………………………………………………………………………… 438
Fuel Injector Removal and Installation………………………………………………………………………………………………………………………………………………………………… 438
Fuel Injector Inspection…………………………………………………………………………………………………………………………………………………………………………….. 439
Fuel Pressure Regulator Removal and Installation……………………………………………………………………………………………………………………………………………………….. 440
Fuel Pressure Regulator Inspection……………………………………………………………………………………………………………………………………………………………………. 441
Fuel Filler Cap Inspection…………………………………………………………………………………………………………………………………………………………………………… 441
Fuel Tank Inlet Valve Removal and Installation…………………………………………………………………………………………………………………………………………………………. 441
Fuel Tank Inlet Valve Inspection……………………………………………………………………………………………………………………………………………………………………… 442
Fuel Tank Removal and Installation……………………………………………………………………………………………………………………………………………………………………. 443
Fuel Tank Inspection………………………………………………………………………………………………………………………………………………………………………………… 444
Fuel Tank Purging Procedure………………………………………………………………………………………………………………………………………………………………………….. 444
Fuel Pump On-Vehicle Inspection………………………………………………………………………………………………………………………………………………………………………. 445
Fuel Pump Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………………. 445
Main Fuel Level Gauge Removal and Installation…………………………………………………………………………………………………………………………………………………………. 446
Fuel Pump Inspection………………………………………………………………………………………………………………………………………………………………………………… 447
Sub Fuel Level Gauge Removal and Installation………………………………………………………………………………………………………………………………………………………….. 447
Sub Fuel Level Gauge Inspection………………………………………………………………………………………………………………………………………………………………………. 447
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 448
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 448
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 449
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 449
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 449
Ignition System……………………………………………………………………………………………………………………………………………………………………………………………. 450
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 450
Ignition System Construction…………………………………………………………………………………………………………………………………………………………………………. 450
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 451
Ignition System Wiring Circuit Diagram………………………………………………………………………………………………………………………………………………………………… 451
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 452
Ignition System Components Location…………………………………………………………………………………………………………………………………………………………………… 452
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 452
Ignition System Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………….. 452
Ignition System Check……………………………………………………………………………………………………………………………………………………………………………….. 453
Ignition Spark Check………………………………………………………………………………………………………………………………………………………………………………… 454
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 455
Ignition Timing Inspection…………………………………………………………………………………………………………………………………………………………………………… 455
Ignition Coil Assembly (Igniter and Ignition Coil) Removal and Installation……………………………………………………………………………………………………………………………….. 456
Ignition Coil Assembly (Igniter and Ignition Coil) Inspection……………………………………………………………………………………………………………………………………………. 456
Spark Plug Removal and Installation…………………………………………………………………………………………………………………………………………………………………… 456
Spark Plug Inspection……………………………………………………………………………………………………………………………………………………………………………….. 456
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 457
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 457
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 457
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 457
Starting System……………………………………………………………………………………………………………………………………………………………………………………………. 458
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 458
Cranking Circuit Introduction………………………………………………………………………………………………………………………………………………………………………… 458
Starting Motor Circuit Description……………………………………………………………………………………………………………………………………………………………………. 458
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 459
Cranking System Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………….. 459
Starting Motor Performance Test………………………………………………………………………………………………………………………………………………………………………. 461
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 462
Starting Motor Components……………………………………………………………………………………………………………………………………………………………………………. 462
Starting Motor Dismounting and Remounting……………………………………………………………………………………………………………………………………………………………… 463
Starting Motor Disassembly and Assembly……………………………………………………………………………………………………………………………………………………………….. 463
Starting Motor Inspection……………………………………………………………………………………………………………………………………………………………………………. 467
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 470
Starting Motor Specifications………………………………………………………………………………………………………………………………………………………………………… 470
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 470
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 470
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 470
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 470
Charging System……………………………………………………………………………………………………………………………………………………………………………………………. 471
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 471
Battery Description…………………………………………………………………………………………………………………………………………………………………………………. 471
Generator Description……………………………………………………………………………………………………………………………………………………………………………….. 472
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 473
Battery Inspection………………………………………………………………………………………………………………………………………………………………………………….. 473
Generator Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………………….. 474
Generator Test (Undercharged Battery Check)……………………………………………………………………………………………………………………………………………………………. 475
Generator Test (Overcharged Battery Check)…………………………………………………………………………………………………………………………………………………………….. 476
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 476
Jump Starting in Case of Emergency……………………………………………………………………………………………………………………………………………………………………. 476
Battery Dismounting and Remounting……………………………………………………………………………………………………………………………………………………………………. 477
Generator Dismounting and Remounting………………………………………………………………………………………………………………………………………………………………….. 478
Generator Components………………………………………………………………………………………………………………………………………………………………………………… 479
Generator Disassembly and Assembly……………………………………………………………………………………………………………………………………………………………………. 480
Generator Inspection………………………………………………………………………………………………………………………………………………………………………………… 483
Water Pump and Generator Drive Belt Inspection and Adjustment……………………………………………………………………………………………………………………………………………. 484
Water Pump and Generator Drive Belt Removal and Installation…………………………………………………………………………………………………………………………………………….. 485
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 486
Charging System Specifications……………………………………………………………………………………………………………………………………………………………………….. 486
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 486
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 486
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 486
Exhaust System…………………………………………………………………………………………………………………………………………………………………………………………….. 487
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 487
Exhaust System Caution………………………………………………………………………………………………………………………………………………………………………………. 487
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 487
Exhaust System Description…………………………………………………………………………………………………………………………………………………………………………… 487
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 487
Exhaust System Check………………………………………………………………………………………………………………………………………………………………………………… 487
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 488
Exhaust System Components……………………………………………………………………………………………………………………………………………………………………………. 488
Exhaust Manifold Removal and Installation……………………………………………………………………………………………………………………………………………………………… 489
Muffler Removal and Installation……………………………………………………………………………………………………………………………………………………………………… 491
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 491
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 491
Suspension……………………………………………………………………………………………………………………………………………………………………………………………………. 493
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 495
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 495
Precautions on Suspension……………………………………………………………………………………………………………………………………………………………………………. 495
Suspension General Diagnosis………………………………………………………………………………………………………………………………………………………………………………… 496
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 496
Suspension, Wheels and Tires Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………. 496
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 498
Wheel Alignment Specifications……………………………………………………………………………………………………………………………………………………………………….. 498
Front Suspension…………………………………………………………………………………………………………………………………………………………………………………………… 499
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 499
Front Suspension Construction………………………………………………………………………………………………………………………………………………………………………… 499
Front Wheel Alignment Construction……………………………………………………………………………………………………………………………………………………………………. 500
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 500
Front Wheel Alignment Inspection and Adjustment………………………………………………………………………………………………………………………………………………………… 500
Front Strut Assembly Components………………………………………………………………………………………………………………………………………………………………………. 502
Front Strut Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………….. 503
Front Strut Assembly Disassembly and Assembly………………………………………………………………………………………………………………………………………………………….. 505
Front Strut Assembly Check…………………………………………………………………………………………………………………………………………………………………………… 506
Front Wheel Hub Assembly and Steering Knuckle Components………………………………………………………………………………………………………………………………………………… 507
Front Wheel Hub Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………. 507
Steering Knuckle Removal and Installation……………………………………………………………………………………………………………………………………………………………… 509
Front Wheel Hub, Disc, Nut and Bearing Check…………………………………………………………………………………………………………………………………………………………… 511
Suspension Control Arm Removal and Installation………………………………………………………………………………………………………………………………………………………… 511
Suspension Control Arm / Bushing Disassembly and Assembly……………………………………………………………………………………………………………………………………………….. 513
Suspension Control Arm / Steering Knuckle Check………………………………………………………………………………………………………………………………………………………… 514
Suspension Control Arm Bushing Check………………………………………………………………………………………………………………………………………………………………….. 514
Suspension Control Arm Joint Check……………………………………………………………………………………………………………………………………………………………………. 514
Front Suspension Frame, Stabilizer Bar and/or Bushings Components………………………………………………………………………………………………………………………………………… 515
Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation……………………………………………………………………………………………………………………………. 516
Front Suspension Frame Check…………………………………………………………………………………………………………………………………………………………………………. 520
Front Stabilizer Bar, Bushing and/or Joint Check……………………………………………………………………………………………………………………………………………………….. 520
Front Suspension Fasteners Check……………………………………………………………………………………………………………………………………………………………………… 521
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 521
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 521
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 522
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 522
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 522
Rear Suspension……………………………………………………………………………………………………………………………………………………………………………………………. 523
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 523
Rear Suspension Construction…………………………………………………………………………………………………………………………………………………………………………. 523
Rear Wheel Alignment Construction…………………………………………………………………………………………………………………………………………………………………….. 524
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 524
Rear Wheel Alignment Inspection and Adjustment…………………………………………………………………………………………………………………………………………………………. 524
Rear Shock Absorber and Rear Coil Spring Components…………………………………………………………………………………………………………………………………………………….. 526
Rear Shock Absorber Removal and Installation…………………………………………………………………………………………………………………………………………………………… 527
Shock Absorber Check………………………………………………………………………………………………………………………………………………………………………………… 528
Rear Coil Spring and Bump Stopper Removal and Installation………………………………………………………………………………………………………………………………………………. 528
Rear Coil Spring Check………………………………………………………………………………………………………………………………………………………………………………. 530
Rod and Arm Components………………………………………………………………………………………………………………………………………………………………………………. 531
Control Rod Removal and Installation………………………………………………………………………………………………………………………………………………………………….. 532
Control Rod / Bushing Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………. 534
Control Rod Check…………………………………………………………………………………………………………………………………………………………………………………… 534
Trailing Rod Removal and Installation…………………………………………………………………………………………………………………………………………………………………. 535
Trailing Rod / Bushing Disassembly and Assembly………………………………………………………………………………………………………………………………………………………… 536
Trailing Rod Check………………………………………………………………………………………………………………………………………………………………………………….. 537
Lower Arm Removal and Installation……………………………………………………………………………………………………………………………………………………………………. 537
Lower Arm / Bushing Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………… 539
Lower Arm Check…………………………………………………………………………………………………………………………………………………………………………………….. 539
Upper Arm Removal and Installation……………………………………………………………………………………………………………………………………………………………………. 540
Upper Arm / Bushing Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………… 541
Upper Arm Check…………………………………………………………………………………………………………………………………………………………………………………….. 542
Rear Suspension Frame Components……………………………………………………………………………………………………………………………………………………………………… 543
Rear Suspension Frame Removal and Installation…………………………………………………………………………………………………………………………………………………………. 544
Rear Suspension frame / Bushing Disassembly and Assembly………………………………………………………………………………………………………………………………………………… 546
Rear Suspension Frame, Bushing and Pad Check…………………………………………………………………………………………………………………………………………………………… 547
Rear Wheel Hub Assembly and Rear Suspension Knuckle Components…………………………………………………………………………………………………………………………………………… 547
Rear Wheel Hub Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………….. 548
Rear Wheel Hub Assembly, Wheel Bearing and Wheel Stud Inspection…………………………………………………………………………………………………………………………………………. 550
Rear Wheel Disc, Nut and Bearing Check………………………………………………………………………………………………………………………………………………………………… 550
Rear Suspension knuckle Removal and Installation……………………………………………………………………………………………………………………………………………………….. 551
Rear Suspension Knuckle Check………………………………………………………………………………………………………………………………………………………………………… 554
Rear Suspension Fasteners Check………………………………………………………………………………………………………………………………………………………………………. 554
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 555
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 555
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 556
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 556
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 556
Wheels and Tires…………………………………………………………………………………………………………………………………………………………………………………………… 557
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 557
Tires Description…………………………………………………………………………………………………………………………………………………………………………………… 557
Wheels Description………………………………………………………………………………………………………………………………………………………………………………….. 558
Irregular and/or Premature Wear Description……………………………………………………………………………………………………………………………………………………………. 559
Wear Indicators Description………………………………………………………………………………………………………………………………………………………………………….. 559
Radial Tire Waddle Description……………………………………………………………………………………………………………………………………………………………………….. 559
Radial Tire Lead / Pull Description…………………………………………………………………………………………………………………………………………………………………… 561
Balancing Wheels Description…………………………………………………………………………………………………………………………………………………………………………. 561
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 561
General Balance Procedures…………………………………………………………………………………………………………………………………………………………………………… 561
Tire Rotation………………………………………………………………………………………………………………………………………………………………………………………. 562
Wheel Removal and Installation……………………………………………………………………………………………………………………………………………………………………….. 562
Tire Mounting and Dismounting………………………………………………………………………………………………………………………………………………………………………… 563
Tire Repair………………………………………………………………………………………………………………………………………………………………………………………… 563
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 563
Wheels and Tires Specifications………………………………………………………………………………………………………………………………………………………………………. 563
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 563
Driveline / Axle………………………………………………………………………………………………………………………………………………………………………………………………. 565
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 567
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 567
Precautions for Driveline / Axle……………………………………………………………………………………………………………………………………………………………………… 567
Drive Shaft / Axle…………………………………………………………………………………………………………………………………………………………………………………………. 568
Front…………………………………………………………………………………………………………………………………………………………………………………………………. 568
General Description…………………………………………………………………………………………………………………………………………………………………………………. 568
Front Drive Shaft Construction……………………………………………………………………………………………………………………………………………………………………. 568
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………. 568
Front Drive Shaft Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….. 568
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………. 569
Front Drive Shaft Boot and Joint Check…………………………………………………………………………………………………………………………………………………………….. 569
Front Drive Shaft Components……………………………………………………………………………………………………………………………………………………………………… 569
Front Drive Shaft Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………. 570
Front Drive Shaft Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………. 570
Specifications……………………………………………………………………………………………………………………………………………………………………………………… 573
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………….. 573
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………….. 573
Recommended Service Material……………………………………………………………………………………………………………………………………………………………………… 573
Special Tool……………………………………………………………………………………………………………………………………………………………………………………. 573
Rear………………………………………………………………………………………………………………………………………………………………………………………………….. 574
General Description…………………………………………………………………………………………………………………………………………………………………………………. 574
Rear Drive Shaft Construction…………………………………………………………………………………………………………………………………………………………………….. 574
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………. 574
Rear Drive Shaft Components………………………………………………………………………………………………………………………………………………………………………. 574
Rear Drive Shaft Assembly Removal and Installation………………………………………………………………………………………………………………………………………………….. 575
Rear Drive Shaft Disassembly and Assembly………………………………………………………………………………………………………………………………………………………….. 575
Specifications……………………………………………………………………………………………………………………………………………………………………………………… 576
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………….. 576
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………….. 576
Recommended Service Material……………………………………………………………………………………………………………………………………………………………………… 576
Special Tool……………………………………………………………………………………………………………………………………………………………………………………. 576
Differential………………………………………………………………………………………………………………………………………………………………………………………………. 577
Front…………………………………………………………………………………………………………………………………………………………………………………………………. 577
General Description…………………………………………………………………………………………………………………………………………………………………………………. 577
Front Differential Construction…………………………………………………………………………………………………………………………………………………………………… 577
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………. 577
Front Differential Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………. 577
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………. 578
Front Differential Oil Change…………………………………………………………………………………………………………………………………………………………………….. 578
Front Differential Unit Components………………………………………………………………………………………………………………………………………………………………… 579
Front Differential Dismounting and Remounting………………………………………………………………………………………………………………………………………………………. 579
Front Differential Components…………………………………………………………………………………………………………………………………………………………………….. 580
Front Differential Assembly Disassembly and Reassembly………………………………………………………………………………………………………………………………………………. 581
Front Differential Inspection…………………………………………………………………………………………………………………………………………………………………….. 594
Specifications……………………………………………………………………………………………………………………………………………………………………………………… 594
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………….. 594
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………….. 594
Recommended Service Material……………………………………………………………………………………………………………………………………………………………………… 594
Special Tool……………………………………………………………………………………………………………………………………………………………………………………. 594
Rear………………………………………………………………………………………………………………………………………………………………………………………………….. 597
General Description…………………………………………………………………………………………………………………………………………………………………………………. 597
Rear Differential Construction……………………………………………………………………………………………………………………………………………………………………. 597
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………. 597
Rear Differential Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….. 597
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………. 597
Rear Differential Oil Change……………………………………………………………………………………………………………………………………………………………………… 597
Rear Differential Unit Components…………………………………………………………………………………………………………………………………………………………………. 597
Rear Differential Dismounting and Remounting……………………………………………………………………………………………………………………………………………………….. 598
Rear Differential Components……………………………………………………………………………………………………………………………………………………………………… 598
Rear Differential Assembly Disassembly and Reassembly……………………………………………………………………………………………………………………………………………….. 599
Rear Differential Inspection……………………………………………………………………………………………………………………………………………………………………… 611
Specifications……………………………………………………………………………………………………………………………………………………………………………………… 611
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………….. 611
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………….. 612
Recommended Service Material……………………………………………………………………………………………………………………………………………………………………… 612
Special Tool……………………………………………………………………………………………………………………………………………………………………………………. 612
Transfer………………………………………………………………………………………………………………………………………………………………………………………………….. 615
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 615
Transfer Warning……………………………………………………………………………………………………………………………………………………………………………………. 615
Precautions in Diagnosing Trouble…………………………………………………………………………………………………………………………………………………………………….. 615
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 615
Transfer Description………………………………………………………………………………………………………………………………………………………………………………… 615
Transfer Shift Control System Components………………………………………………………………………………………………………………………………………………………………. 616
4WD Control System Description……………………………………………………………………………………………………………………………………………………………………….. 617
Function of 4WD Control System Component………………………………………………………………………………………………………………………………………………………………. 619
4WD Control System Operation…………………………………………………………………………………………………………………………………………………………………………. 619
4WD Control System Wiring Circuit Diagram……………………………………………………………………………………………………………………………………………………………… 624
Terminal Arrangement of 4WD Control Module…………………………………………………………………………………………………………………………………………………………….. 625
Input / Output Signal Table of 4WD Control Module………………………………………………………………………………………………………………………………………………………. 625
On-Board Diagnostic System Description………………………………………………………………………………………………………………………………………………………………… 626
CAN Communication System Description………………………………………………………………………………………………………………………………………………………………….. 627
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 627
4WD Control System Check…………………………………………………………………………………………………………………………………………………………………………….. 627
Transfer Position Indicator Operation Check……………………………………………………………………………………………………………………………………………………………. 630
4WD Control System Operation Inspection……………………………………………………………………………………………………………………………………………………………….. 630
Visual Inspection…………………………………………………………………………………………………………………………………………………………………………………… 631
DTC Check………………………………………………………………………………………………………………………………………………………………………………………….. 632
DTC Clearance………………………………………………………………………………………………………………………………………………………………………………………. 633
DTC Table………………………………………………………………………………………………………………………………………………………………………………………….. 633
Fail-Safe Table…………………………………………………………………………………………………………………………………………………………………………………….. 634
Scan Tool Data……………………………………………………………………………………………………………………………………………………………………………………… 635
Scan Tool Data Definitions…………………………………………………………………………………………………………………………………………………………………………… 635
4WD Control Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………………… 636
Transfer Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops………………………………………………………………………………………………………………………… 637
Transfer Position Indicator Remains ON Steady at Ignition Switch ON………………………………………………………………………………………………………………………………………. 639
DTC C1213: Transfer Switch Circuit Open……………………………………………………………………………………………………………………………………………………………….. 640
DTC C1214: Transfer Switch Circuit Short………………………………………………………………………………………………………………………………………………………………. 641
DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open……………………………………………………………………. 643
DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short………………………………………………………………….. 645
DTC C1227: 4L/N Switch Circuit Open…………………………………………………………………………………………………………………………………………………………………… 647
DTC C1228: 4L/N Switch Circuit Short………………………………………………………………………………………………………………………………………………………………….. 648
DTC C1230: Transfer Actuator Circuit Malfunction……………………………………………………………………………………………………………………………………………………….. 650
DTC C1237: Center Differential Lock Switch Circuit Open…………………………………………………………………………………………………………………………………………………. 652
DTC C1238: Center Differential Lock Switch Circuit Short………………………………………………………………………………………………………………………………………………… 654
DTC C1240: 4WD Control Module Power Supply Circuit Malfunction…………………………………………………………………………………………………………………………………………… 656
DTC C1243: Internal Circuit Malfunction of 4WD Control Module……………………………………………………………………………………………………………………………………………. 657
DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short……………………………………………………………………………………………………………………………………………… 657
DTC U1073: Control Module Communication Buss Off……………………………………………………………………………………………………………………………………………………….. 659
DTC U1100: Lost Communication with ECM………………………………………………………………………………………………………………………………………………………………… 661
DTC U1101: Lost Communication with TCM………………………………………………………………………………………………………………………………………………………………… 663
DTC U1121: Lost Communication with ABS Hydraulic Unit / Control Module……………………………………………………………………………………………………………………………………. 665
Inspection of 4WD Control Module and Its Circuits………………………………………………………………………………………………………………………………………………………. 667
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 669
Transfer Oil Level Check…………………………………………………………………………………………………………………………………………………………………………….. 669
Transfer Oil Change…………………………………………………………………………………………………………………………………………………………………………………. 669
Transfer Oil Seal Removal and Installation…………………………………………………………………………………………………………………………………………………………….. 670
Transfer Switch Removal and Installation………………………………………………………………………………………………………………………………………………………………. 671
Transfer Switch Inspection…………………………………………………………………………………………………………………………………………………………………………… 671
4WD Control Module Removal and Installation……………………………………………………………………………………………………………………………………………………………. 672
Transfer Assembly Dismounting and Remounting…………………………………………………………………………………………………………………………………………………………… 672
Transfer Assembly Components…………………………………………………………………………………………………………………………………………………………………………. 674
Transfer Assembly Disassembly and Reassembly…………………………………………………………………………………………………………………………………………………………… 675
Transfer Assembly Inspection…………………………………………………………………………………………………………………………………………………………………………. 683
Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components……………………………………………………………………………………………… 685
Input Gear Assembly Disassembly and Reassembly…………………………………………………………………………………………………………………………………………………………. 686
Counter Gear Assembly Disassembly and Reassembly……………………………………………………………………………………………………………………………………………………….. 687
Front Output Shaft Assembly Disassembly and Reassembly………………………………………………………………………………………………………………………………………………….. 687
Rear Output Shaft Assembly Disassembly and Reassembly…………………………………………………………………………………………………………………………………………………… 688
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 689
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 689
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 690
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 690
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 690
Propeller Shafts…………………………………………………………………………………………………………………………………………………………………………………………… 692
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 692
Propeller Shaft Caution……………………………………………………………………………………………………………………………………………………………………………… 692
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 692
Propeller Shaft Construction…………………………………………………………………………………………………………………………………………………………………………. 692
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 693
Propeller Shaft Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………….. 693
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 693
Propeller Shaft Joint Check………………………………………………………………………………………………………………………………………………………………………….. 693
Propeller Shaft Removal and Installation………………………………………………………………………………………………………………………………………………………………. 693
Propeller Shaft Disassembly and Assembly………………………………………………………………………………………………………………………………………………………………. 695
Propeller Shaft Inspection…………………………………………………………………………………………………………………………………………………………………………… 697
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 697
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 697
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 697
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 697
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 697
Brakes……………………………………………………………………………………………………………………………………………………………………………………………………….. 699
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 701
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 701
Precautions for Brakes………………………………………………………………………………………………………………………………………………………………………………. 701
Brake Control System and Diagnosis…………………………………………………………………………………………………………………………………………………………………………… 702
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 702
Brakes Construction…………………………………………………………………………………………………………………………………………………………………………………. 702
Front Brake Hose / Pipe Construction………………………………………………………………………………………………………………………………………………………………….. 703
Rear Brake Hose / Pipe Construction…………………………………………………………………………………………………………………………………………………………………… 704
Master Cylinder Assembly Construction…………………………………………………………………………………………………………………………………………………………………. 704
Booster Assembly Construction………………………………………………………………………………………………………………………………………………………………………… 705
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 705
Brake Diagnosis Note………………………………………………………………………………………………………………………………………………………………………………… 705
Brakes Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………………….. 706
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 708
Excessive Pedal Travel Check…………………………………………………………………………………………………………………………………………………………………………. 708
Brake Pedal Play Check………………………………………………………………………………………………………………………………………………………………………………. 708
Brake Fluid Level Check……………………………………………………………………………………………………………………………………………………………………………… 708
Air Bleeding of Brake System…………………………………………………………………………………………………………………………………………………………………………. 709
Brake Pedal Free Height Adjustment……………………………………………………………………………………………………………………………………………………………………. 710
Brake Light Switch Adjustment………………………………………………………………………………………………………………………………………………………………………… 710
Brake Flexible Hose and Pipe Check……………………………………………………………………………………………………………………………………………………………………. 711
Master Cylinder Check……………………………………………………………………………………………………………………………………………………………………………….. 711
Flushing Brake Hydraulic System………………………………………………………………………………………………………………………………………………………………………. 711
Booster Operation Check……………………………………………………………………………………………………………………………………………………………………………… 711
Front Brake Hose / Pipe Removal and Installation……………………………………………………………………………………………………………………………………………………….. 712
Rear Brake Hose / Pipe Removal and Installation………………………………………………………………………………………………………………………………………………………… 713
Master Cylinder Components…………………………………………………………………………………………………………………………………………………………………………… 713
Master Cylinder Reservoir Removal and Installation……………………………………………………………………………………………………………………………………………………… 714
Master Cylinder Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………. 715
Master Cylinder Assembly Inspection…………………………………………………………………………………………………………………………………………………………………… 716
Brake Booster Components…………………………………………………………………………………………………………………………………………………………………………….. 717
Brake Booster Removal and Installation………………………………………………………………………………………………………………………………………………………………… 717
Booster Push Rod Clevis Adjustment……………………………………………………………………………………………………………………………………………………………………. 718
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 719
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 719
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 719
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 719
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 719
Front Brakes………………………………………………………………………………………………………………………………………………………………………………………………. 720
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 720
Front Disc Brake Caliper Assembly Construction…………………………………………………………………………………………………………………………………………………………. 720
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 721
Front Disc Brake Components………………………………………………………………………………………………………………………………………………………………………….. 721
Front Disc Brake Pad On-Vehicle Check…………………………………………………………………………………………………………………………………………………………………. 722
Front Disc Brake Pad Removal and Installation………………………………………………………………………………………………………………………………………………………….. 722
Front Brake Disc and Pad Inspection…………………………………………………………………………………………………………………………………………………………………… 723
Front Disc Brake Caliper Removal and Installation………………………………………………………………………………………………………………………………………………………. 724
Front Disc Brake Caliper Disassembly and Assembly………………………………………………………………………………………………………………………………………………………. 726
Front Disc Brake Caliper Inspection…………………………………………………………………………………………………………………………………………………………………… 727
Front Brake Disc Removal and Installation……………………………………………………………………………………………………………………………………………………………… 728
Front Brake Disc Inspection………………………………………………………………………………………………………………………………………………………………………….. 728
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 729
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 729
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 729
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 729
Rear Brakes……………………………………………………………………………………………………………………………………………………………………………………………….. 730
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 730
Rear Drum Brake Assembly Construction…………………………………………………………………………………………………………………………………………………………………. 730
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 730
Rear Drum Brake Assembly Components…………………………………………………………………………………………………………………………………………………………………… 730
Rear Brake Drum Removal and Installation………………………………………………………………………………………………………………………………………………………………. 731
Rear Brake Drum and Shoe Inspection…………………………………………………………………………………………………………………………………………………………………… 732
Rear Brake Shoe On-Vehicle Check……………………………………………………………………………………………………………………………………………………………………… 732
Rear Brake Shoe Removal and Installation………………………………………………………………………………………………………………………………………………………………. 733
Rear Brake Shoe Inspection…………………………………………………………………………………………………………………………………………………………………………… 734
Wheel Cylinder Removal and Installation……………………………………………………………………………………………………………………………………………………………….. 734
Wheel Cylinder Inspection……………………………………………………………………………………………………………………………………………………………………………. 735
Rear Brake Back Plate Removal and Installation…………………………………………………………………………………………………………………………………………………………. 736
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 737
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 737
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 737
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 737
Parking Brake……………………………………………………………………………………………………………………………………………………………………………………………… 738
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 738
Parking Brake Cable Location…………………………………………………………………………………………………………………………………………………………………………. 738
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 739
Parking Brake Check and Adjustment……………………………………………………………………………………………………………………………………………………………………. 739
Parking Brake Lever Removal and Installation…………………………………………………………………………………………………………………………………………………………… 740
Parking Brake Cable Removal and Installation…………………………………………………………………………………………………………………………………………………………… 741
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 741
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 741
ABS………………………………………………………………………………………………………………………………………………………………………………………………………. 742
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 742
Precautions in Diagnosing Troubles……………………………………………………………………………………………………………………………………………………………………. 742
Precautions in On-Vehicle Service…………………………………………………………………………………………………………………………………………………………………….. 742
Precautions in Hydraulic Unit Operation Check………………………………………………………………………………………………………………………………………………………….. 742
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 742
ABS Description…………………………………………………………………………………………………………………………………………………………………………………….. 742
ABS Hydraulic Unit / Control Module Assembly Description………………………………………………………………………………………………………………………………………………… 743
CAN Communication System Description………………………………………………………………………………………………………………………………………………………………….. 743
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 744
ABS Schematic………………………………………………………………………………………………………………………………………………………………………………………. 744
ABS Wiring Circuit Diagram…………………………………………………………………………………………………………………………………………………………………………… 745
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 747
ABS Components Location……………………………………………………………………………………………………………………………………………………………………………… 747
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 748
ABS Check………………………………………………………………………………………………………………………………………………………………………………………….. 748
ABS Warning Lamp Check………………………………………………………………………………………………………………………………………………………………………………. 750
EBD Warning Lamp (Brake Warning Lamp) Check……………………………………………………………………………………………………………………………………………………………. 750
DTC Check………………………………………………………………………………………………………………………………………………………………………………………….. 751
DTC Table………………………………………………………………………………………………………………………………………………………………………………………….. 751
DTC Clearance………………………………………………………………………………………………………………………………………………………………………………………. 752
Scan Tool Data……………………………………………………………………………………………………………………………………………………………………………………… 752
ABS Warning Lamp Does Not Come ON at Ignition Switch ON…………………………………………………………………………………………………………………………………………………. 753
ABS Warning Lamp Comes ON Steady……………………………………………………………………………………………………………………………………………………………………… 754
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady…………………………………………………………………………………………………………………………………………………… 756
Serial Data Link Circuit Check……………………………………………………………………………………………………………………………………………………………………….. 757
DTC C1015: G Sensor Circuit………………………………………………………………………………………………………………………………………………………………………….. 759
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder……………………………………………………………. 760
DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit…. 762
DTC C1057: Power Source Circuit………………………………………………………………………………………………………………………………………………………………………. 763
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit…………………………………………………………………………………………………………………………………………………… 764
DTC C1063: Solenoid Valve Power Supply Driver Circuit…………………………………………………………………………………………………………………………………………………… 765
DTC C1071: ABS Control Module………………………………………………………………………………………………………………………………………………………………………… 766
DTC U1073: Control Module Communication Bus Off………………………………………………………………………………………………………………………………………………………… 767
DTC U1100: Lost Communication with ECM (Reception Error)………………………………………………………………………………………………………………………………………………… 768
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 769
ABS Hydraulic Unit Operation Check……………………………………………………………………………………………………………………………………………………………………. 769
ABS Hydraulic Unit / Control Module Assembly Components…………………………………………………………………………………………………………………………………………………. 770
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection……………………………………………………………………………………………………………………………………….. 771
ABS Hydraulic Unit / Control Module Assembly Removal and Installation…………………………………………………………………………………………………………………………………….. 771
Front Wheel Speed Sensor On-Vehicle Inspection…………………………………………………………………………………………………………………………………………………………. 773
Front Wheel Speed Sensor Removal and Installation………………………………………………………………………………………………………………………………………………………. 774
Front Wheel Speed Sensor Inspection…………………………………………………………………………………………………………………………………………………………………… 775
Rear Wheel Speed Sensor On-Vehicle Inspection………………………………………………………………………………………………………………………………………………………….. 775
Rear Wheel Speed Sensor Removal and Installation……………………………………………………………………………………………………………………………………………………….. 775
Rear Wheel Speed Sensor Inspection……………………………………………………………………………………………………………………………………………………………………. 776
Front Wheel Encoder On-Vehicle Inspection……………………………………………………………………………………………………………………………………………………………… 776
Front Wheel Encoder Removal and Installation…………………………………………………………………………………………………………………………………………………………… 776
Rear Wheel Encoder On-Vehicle Inspection………………………………………………………………………………………………………………………………………………………………. 776
Rear Wheel Encoder Removal and Installation……………………………………………………………………………………………………………………………………………………………. 776
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 777
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 777
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 777
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 777
Transmission / Transaxle……………………………………………………………………………………………………………………………………………………………………………………….. 779
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 782
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 782
Precautions for Transmission / Transaxle………………………………………………………………………………………………………………………………………………………………. 782
Automatic Transmission/Transaxle…………………………………………………………………………………………………………………………………………………………………………….. 783
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 783
Precautions in Diagnosing Trouble…………………………………………………………………………………………………………………………………………………………………….. 783
General Service Procedure Information…………………………………………………………………………………………………………………………………………………………………. 783
Precautions for Disassembly and Reassembly…………………………………………………………………………………………………………………………………………………………….. 783
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 784
Automatic Transmission Description……………………………………………………………………………………………………………………………………………………………………. 784
Clutch / Brake Functions of Automatic Transmission……………………………………………………………………………………………………………………………………………………… 787
Table of A/T Component Operation……………………………………………………………………………………………………………………………………………………………………… 788
CAN Communication System Description………………………………………………………………………………………………………………………………………………………………….. 788
Electronic Shift Control Input / Output Table………………………………………………………………………………………………………………………………………………………….. 789
Brake Interlock System Description……………………………………………………………………………………………………………………………………………………………………. 792
A/T Diagnosis General Description…………………………………………………………………………………………………………………………………………………………………….. 792
On-Board Diagnostic System Description………………………………………………………………………………………………………………………………………………………………… 792
Schematic and Routing Diagram……………………………………………………………………………………………………………………………………………………………………………. 793
Automatic Gear Shift Table…………………………………………………………………………………………………………………………………………………………………………… 793
Bearing and Race Installation Diagram…………………………………………………………………………………………………………………………………………………………………. 795
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 796
Electronic Shift Control System Components Location…………………………………………………………………………………………………………………………………………………….. 796
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 797
A/T System Check……………………………………………………………………………………………………………………………………………………………………………………. 797
Malfunction Indicator Lamp (MIL) Check………………………………………………………………………………………………………………………………………………………………… 799
DTC Table………………………………………………………………………………………………………………………………………………………………………………………….. 800
DTC Check………………………………………………………………………………………………………………………………………………………………………………………….. 802
DTC Clearance………………………………………………………………………………………………………………………………………………………………………………………. 802
Fail Safe Table…………………………………………………………………………………………………………………………………………………………………………………….. 803
Scan Tool Data……………………………………………………………………………………………………………………………………………………………………………………… 805
Visual Inspection…………………………………………………………………………………………………………………………………………………………………………………… 808
A/T Basic Check…………………………………………………………………………………………………………………………………………………………………………………….. 808
Road Test………………………………………………………………………………………………………………………………………………………………………………………….. 809
Manual Road Test……………………………………………………………………………………………………………………………………………………………………………………. 810
Stall Test…………………………………………………………………………………………………………………………………………………………………………………………. 811
Time Lag Test………………………………………………………………………………………………………………………………………………………………………………………. 812
Line Pressure Test………………………………………………………………………………………………………………………………………………………………………………….. 812
Engine Brake Test…………………………………………………………………………………………………………………………………………………………………………………… 814
“P” Range Test……………………………………………………………………………………………………………………………………………………………………………………… 814
A/T Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………………………….. 814
No Gear Shift to 5th gear……………………………………………………………………………………………………………………………………………………………………………. 818
No Lock-Up Occurs…………………………………………………………………………………………………………………………………………………………………………………… 819
DTC P0705: Transmission Range Sensor Circuit Malfunction………………………………………………………………………………………………………………………………………………… 820
DTC P0707: Transmission Range Sensor Circuit Low……………………………………………………………………………………………………………………………………………………….. 822
DTC P0711: Transmission Fluid Temperature Sensor Range / Performance……………………………………………………………………………………………………………………………………… 823
DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low…………………………………………………………………………………………………………………………………………. 824
DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High………………………………………………………………………………………………………………………………………… 825
DTC P0717: Input / Turbine Speed Sensor Circuit No Signal……………………………………………………………………………………………………………………………………………….. 826
DTC P0722: Output Speed Sensor Circuit No Signal……………………………………………………………………………………………………………………………………………………….. 828
DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON…………………………………………………………………………………………………………………………….. 829
DTC P0751 / P0752: Shift Solenoid-A Performance or Stuck OFF / Shift Solenoid-A Stuck ON……………………………………………………………………………………………………………………. 830
DTC P0756 / P0757: Shift Solenoid-B Performance or Stuck OFF / Shift Solenoid-B Stuck ON……………………………………………………………………………………………………………………. 831
DTC P0771 / P0772: Shift Solenoid-E Performance or Stuck OFF / Shift Solenoid-E Stuck ON……………………………………………………………………………………………………………………. 832
DTC P0781: 1-2 Shift………………………………………………………………………………………………………………………………………………………………………………… 833
DTC P0797: Pressure Control Solenoid “C” Stuck ON………………………………………………………………………………………………………………………………………………………. 834
DTC P0962 / P0966 / P0970: Pressure Control Solenoid “A” Control Circuit Low / Pressure Control Solenoid “B” Control Circuit Low / Pressure Control Solenoid “C” Control Circuit Low………………………………….. 836
DTC P0963 / P0967 / P0971: Pressure Control Solenoid “A” Control Circuit High / Pressure Control Solenoid “B” Control Circuit High / Pressure Control Solenoid “C” Control Circuit High……………………………….. 838
DTC P0973 / P0976 / P0985: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low / Shift Solenoid “E” Control Circuit Low……………………………………………………………….. 839
DTC P0974 / P0977 / P0986: Shift Solenoid “A” Control Circuit High / Shift Solenoid “B” Control Circuit High / Shift Solenoid “E” Control Circuit High…………………………………………………………….. 840
DTC P1702: Internal Control Module Memory Check Sum Error……………………………………………………………………………………………………………………………………………….. 842
DTC P1703: CAN Invalid Data – TCM…………………………………………………………………………………………………………………………………………………………………….. 842
DTC P1723: Range Select Switch Malfunction…………………………………………………………………………………………………………………………………………………………….. 843
DTC P1874: 4L Switch Circuit Malfunction (Short)……………………………………………………………………………………………………………………………………………………….. 844
DTC P1875: 4L Switch Circuit Malfunction (Open)………………………………………………………………………………………………………………………………………………………… 845
DTC P2742: Transmission Fluid Temperature Sensor “B” Circuit Low…………………………………………………………………………………………………………………………………………. 847
DTC P2743: Transmission Fluid Temperature Sensor “B” Circuit High………………………………………………………………………………………………………………………………………… 848
DTC P2763: Torque Converter Clutch (TCC) Circuit High…………………………………………………………………………………………………………………………………………………… 849
DTC P2764: Torque Converter Clutch (TCC) Circuit Low……………………………………………………………………………………………………………………………………………………. 850
DTC U0073: Control Module Communication Bus Off………………………………………………………………………………………………………………………………………………………… 852
DTC U0100: Lost Communication with ECM………………………………………………………………………………………………………………………………………………………………… 855
DTC U0140: Lost Communication with Body Control Module………………………………………………………………………………………………………………………………………………….. 856
Inspection of TCM and Its Circuits……………………………………………………………………………………………………………………………………………………………………. 857
TCM Power and Ground Circuit Check……………………………………………………………………………………………………………………………………………………………………. 862
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 863
Learning Control Initialization………………………………………………………………………………………………………………………………………………………………………. 863
A/T Fluid Level Check……………………………………………………………………………………………………………………………………………………………………………….. 863
A/T Fluid Change……………………………………………………………………………………………………………………………………………………………………………………. 864
Oil Cooler Hoses Replacement…………………………………………………………………………………………………………………………………………………………………………. 865
Manual Selector Assembly Components…………………………………………………………………………………………………………………………………………………………………… 866
Manual Selector Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………. 866
Select Lever Knob Installation……………………………………………………………………………………………………………………………………………………………………….. 866
Manual Selector Assembly Inspection…………………………………………………………………………………………………………………………………………………………………… 866
“4” Position Switch Inspection……………………………………………………………………………………………………………………………………………………………………….. 867
Mode Select Switch Inspection………………………………………………………………………………………………………………………………………………………………………… 867
Select Cable Component………………………………………………………………………………………………………………………………………………………………………………. 868
Select Cable Adjustment……………………………………………………………………………………………………………………………………………………………………………… 869
Transmission Range Sensor Removal and Installation……………………………………………………………………………………………………………………………………………………… 869
Transmission Range Sensor Inspection and Adjustment…………………………………………………………………………………………………………………………………………………….. 870
Key Interlock Cable Removal and Installation…………………………………………………………………………………………………………………………………………………………… 871
Brake and key Interlock System Inspection……………………………………………………………………………………………………………………………………………………………… 873
Input Shaft Speed Sensor Removal and Installation………………………………………………………………………………………………………………………………………………………. 874
Input Shaft Speed Sensor Inspection…………………………………………………………………………………………………………………………………………………………………… 874
Output Shaft Speed Sensor Removal and Installation……………………………………………………………………………………………………………………………………………………… 874
Output Shaft Speed Sensor Inspection………………………………………………………………………………………………………………………………………………………………….. 875
Solenoid Valves (Shift Solenoid-A, Shift Solenoid-B, Shift Solenoid-E, TCC Solenoid, Pressure Control Solenoid-A, Pressure Control Solenoid-B, and Pressure Control Solenoid-C) Removal and Installation………………… 875
Solenoid Valves (Shift Solenoid-A, Shift Solenoid-B, Shift Solenoid-E, TCC Solenoid, Pressure Control Solenoid-A, Pressure Control Solenoid-B, and Pressure Control Solenoid-C) Inspection…………………………….. 876
Transmission Fluid Temperature Sensor A and B Removal and Installation……………………………………………………………………………………………………………………………………. 878
Transmission Fluid Temperature Sensor A and B Inspection………………………………………………………………………………………………………………………………………………… 880
Transmission Control Module (TCM) Removal and Installation………………………………………………………………………………………………………………………………………………. 880
A/T Relay Inspection………………………………………………………………………………………………………………………………………………………………………………… 881
Oil Cooler Pipes Removal and Installation……………………………………………………………………………………………………………………………………………………………… 881
Automatic Transmission Unit Components………………………………………………………………………………………………………………………………………………………………… 882
Automatic Transmission Assembly Dismounting and Remounting………………………………………………………………………………………………………………………………………………. 883
Automatic Transmission Unit Components………………………………………………………………………………………………………………………………………………………………… 884
Automatic Transmission Unit Disassembly……………………………………………………………………………………………………………………………………………………………….. 885
Oil Pump Assembly Components…………………………………………………………………………………………………………………………………………………………………………. 896
Oil Pump Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………………….. 896
Oil Pump Inspection…………………………………………………………………………………………………………………………………………………………………………………. 899
Clutch Drum & Input Shaft Assembly Components………………………………………………………………………………………………………………………………………………………….. 900
Clutch Drum & Input Shaft Assembly Disassembly…………………………………………………………………………………………………………………………………………………………. 901
Clutch Drum & Input Shaft Assembly Reassembly………………………………………………………………………………………………………………………………………………………….. 905
Clutch Drum & Input Shaft Assembly Inspection………………………………………………………………………………………………………………………………………………………….. 913
Valve Body Assembly Components……………………………………………………………………………………………………………………………………………………………………….. 915
Automatic Transmission Unit Assembly………………………………………………………………………………………………………………………………………………………………….. 916
Automatic Transmission Unit Assembly Inspection………………………………………………………………………………………………………………………………………………………… 934
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 938
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 938
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 939
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 939
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 939
Manual Transmission/Transaxle……………………………………………………………………………………………………………………………………………………………………………….. 941
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 941
Manual Transmission Construction……………………………………………………………………………………………………………………………………………………………………… 941
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 942
Manual Transmission Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………. 942
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 943
Manual Transmission Assembly Components……………………………………………………………………………………………………………………………………………………………….. 943
Gear Shift Control Lever Rear Case Assembly Components………………………………………………………………………………………………………………………………………………….. 944
Gear Shift Lever Front Case Assembly Components………………………………………………………………………………………………………………………………………………………… 945
Gear Shift Shaft and Fork Components………………………………………………………………………………………………………………………………………………………………….. 946
Input Shaft Assembly, Output Shaft Assembly and Countershaft Assembly Components…………………………………………………………………………………………………………………………… 947
Manual Transmission Oil Change……………………………………………………………………………………………………………………………………………………………………….. 948
Transmission Shift Control Lever Removal and Installation……………………………………………………………………………………………………………………………………………….. 949
Transmission Shift Control Lever Inspection……………………………………………………………………………………………………………………………………………………………. 949
Back Up Light Switch Removal and Installation………………………………………………………………………………………………………………………………………………………….. 950
Back Up Light Switch Inspection………………………………………………………………………………………………………………………………………………………………………. 950
Gear Shift Control Lever Rear Case Assembly Removal and Installation……………………………………………………………………………………………………………………………………… 950
Gear Shift Control Lever Rear Case Assembly Disassembly and Reassembly……………………………………………………………………………………………………………………………………. 951
Gear Shift Control Lever Rear Case Assembly Inspection………………………………………………………………………………………………………………………………………………….. 951
Gear Shift Lever Front Case Assembly Removal and Installation……………………………………………………………………………………………………………………………………………. 951
Gear Shift Lever Front Case Assembly Disassembly and Reassembly………………………………………………………………………………………………………………………………………….. 952
Gear Shift Lever Front Case Assembly Inspection………………………………………………………………………………………………………………………………………………………… 953
Engine Rear Mounting Replacement……………………………………………………………………………………………………………………………………………………………………… 953
Manual Transmission Assembly Dismounting and Remounting…………………………………………………………………………………………………………………………………………………. 954
Manual Transmission Unit Disassembly………………………………………………………………………………………………………………………………………………………………….. 956
Manual Transmission Unit Reassembly…………………………………………………………………………………………………………………………………………………………………… 957
Locating Spring Inspection…………………………………………………………………………………………………………………………………………………………………………… 960
Input Shaft Disassembly……………………………………………………………………………………………………………………………………………………………………………… 960
Input Shaft Inspection………………………………………………………………………………………………………………………………………………………………………………. 961
Input Shaft Reassembly………………………………………………………………………………………………………………………………………………………………………………. 962
Countershaft Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………………. 964
Countershaft and Reverse Idle Gear Inspection………………………………………………………………………………………………………………………………………………………….. 967
Output Shaft Disassembly and Assembly…………………………………………………………………………………………………………………………………………………………………. 968
Output Shaft Inspection……………………………………………………………………………………………………………………………………………………………………………… 969
Manual Transmission Front Case Disassembly and Assembly…………………………………………………………………………………………………………………………………………………. 969
Manual Transmission Adapter Case Disassembly and Assembly……………………………………………………………………………………………………………………………………………….. 970
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 970
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 970
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 971
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 971
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 971
Clutch……………………………………………………………………………………………………………………………………………………………………………………………………. 973
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 973
Clutch (Hydraulic Type) Construction………………………………………………………………………………………………………………………………………………………………….. 973
Component Location……………………………………………………………………………………………………………………………………………………………………………………… 974
Clutch Fluid Pipe and Hose Location…………………………………………………………………………………………………………………………………………………………………… 974
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 975
Clutch (Hydraulic Type) Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………… 975
Clutch Pedal Height Inspection……………………………………………………………………………………………………………………………………………………………………….. 976
Clutch Pedal Free Travel Check……………………………………………………………………………………………………………………………………………………………………….. 976
Clutch Fluid Inspection……………………………………………………………………………………………………………………………………………………………………………… 976
Air Bleeding of Clutch System………………………………………………………………………………………………………………………………………………………………………… 976
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 977
Clutch Pedal Position (CPP) Switch Removal and Installation……………………………………………………………………………………………………………………………………………… 977
Clutch Pedal Position (CPP) Switch Inspection and Adjustment…………………………………………………………………………………………………………………………………………….. 977
Clutch Fluid Pipe and Hose Removal and Installation…………………………………………………………………………………………………………………………………………………….. 977
Clutch Fluid Pipe and Hose Inspection…………………………………………………………………………………………………………………………………………………………………. 978
Clutch Master Cylinder Removal and Installation………………………………………………………………………………………………………………………………………………………… 978
Clutch Master Cylinder Inspection…………………………………………………………………………………………………………………………………………………………………….. 979
Clutch Operating Cylinder Assembly Removal and Installation……………………………………………………………………………………………………………………………………………… 979
Clutch Cover, Clutch Disc and Flywheel Components………………………………………………………………………………………………………………………………………………………. 980
Clutch Cover, Clutch Disc and Flywheel Removal and Installation………………………………………………………………………………………………………………………………………….. 981
Clutch Cover, Clutch Disc and Flywheel Inspection………………………………………………………………………………………………………………………………………………………. 982
Specifications…………………………………………………………………………………………………………………………………………………………………………………………. 983
Tightening Torque Specifications……………………………………………………………………………………………………………………………………………………………………… 983
Special Tools and Equipment……………………………………………………………………………………………………………………………………………………………………………… 983
Recommended Service Material…………………………………………………………………………………………………………………………………………………………………………. 983
Special Tool……………………………………………………………………………………………………………………………………………………………………………………….. 983
Steering……………………………………………………………………………………………………………………………………………………………………………………………………… 985
Precautions……………………………………………………………………………………………………………………………………………………………………………………………….. 987
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 987
Precautions for Steering…………………………………………………………………………………………………………………………………………………………………………….. 987
Steering General Diagnosis………………………………………………………………………………………………………………………………………………………………………………….. 988
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 988
Steering Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………………… 988
Steering Wheel and Column…………………………………………………………………………………………………………………………………………………………………………………… 989
Precautions……………………………………………………………………………………………………………………………………………………………………………………………. 989
Service Precautions of Air Bag Steering Wheel and Column………………………………………………………………………………………………………………………………………………… 989
Handling and Storage of Air Bag Steering Wheel and Column……………………………………………………………………………………………………………………………………………….. 989
Disposal of Air Bag Steering Wheel and Column………………………………………………………………………………………………………………………………………………………….. 989
General Description…………………………………………………………………………………………………………………………………………………………………………………….. 989
Steering Wheel and Column Construction………………………………………………………………………………………………………………………………………………………………… 989
Diagnostic Information and Procedures…………………………………………………………………………………………………………………………………………………………………….. 991
Air Bag Steering Wheel and Column Symptom Diagnosis…………………………………………………………………………………………………………………………………………………….. 991
Air Bag Steering Wheel and Column Inspection and Repair Required after Accident……………………………………………………………………………………………………………………………. 991
Diagnosis and Servicing of Air Bag Steering Wheel and Column…………………………………………………………………………………………………………………………………………….. 991
Repair Instructions…………………………………………………………………………………………………………………………………………………………………………………….. 991
Checking Steering Column for Accident Damage…………………………………………………………………………………………………………………………………………………………… 991
Steering Wheel Removal and Installation……………………………………………………………………………………………………………………………………………………………….. 992
Contact Coil Cable Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………. 993
Contact Coil Cable Assembly Inspection………………………………………………………………………………………………………………………………………………………………… 995
Centering Contact Coil Cable Assembly…………………………………………………………………………………………………………………………………………………………………. 995
Steering Column Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………. 995
Steering Column Assembly Inspection…………………………………………………………………………………………………………………………………………………………………… 998
Ignition Switch Cylinder Assembly Removal and Installation (Without Keyless Start System)…………………………………………………………………………………………………………………… 998
Steering Lock Assembly (Ignition Switch) Removal and Installation………………………………………………………………………………………………………………………………………… 999
Adjustable Steering Column Release Lever Inspection…………………………………………………………………………………………………………………………………………………….. 999
Steering Upper Shaft Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………..1000
Steering Upper Shaft Assembly Inspection……………………………………………………………………………………………………………………………………………………………….1001
Steering Lower Shaft Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………..1001
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1002
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1002
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1002
Special Tool………………………………………………………………………………………………………………………………………………………………………………………..1002
Power Assisted Steering System……………………………………………………………………………………………………………………………………………………………………………….1003
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1003
P/S System Note……………………………………………………………………………………………………………………………………………………………………………………..1003
General Description……………………………………………………………………………………………………………………………………………………………………………………..1003
P/S System Construction………………………………………………………………………………………………………………………………………………………………………………1003
Steering Gear Case Construction……………………………………………………………………………………………………………………………………………………………………….1004
P/S Pump Construction………………………………………………………………………………………………………………………………………………………………………………..1004
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1005
P/S Fluid Flow Diagram……………………………………………………………………………………………………………………………………………………………………………….1005
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1005
P/S System Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………………….1005
Steering Wheel Check…………………………………………………………………………………………………………………………………………………………………………………1006
Steering Force Check…………………………………………………………………………………………………………………………………………………………………………………1007
Steering Wheel Recovery Check…………………………………………………………………………………………………………………………………………………………………………1007
Idle Up System Check…………………………………………………………………………………………………………………………………………………………………………………1007
Hydraulic Pressure in P/S Circuit Check………………………………………………………………………………………………………………………………………………………………..1007
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1009
P/S Fluid Change…………………………………………………………………………………………………………………………………………………………………………………….1009
P/S Fluid Level Check………………………………………………………………………………………………………………………………………………………………………………..1009
P/S Fluid Leakage Check………………………………………………………………………………………………………………………………………………………………………………1010
P/S System Air Bleeding Procedure……………………………………………………………………………………………………………………………………………………………………..1010
P/S Pump and A/C Compressor (If Equipped) Drive Belt Inspection and Adjustment……………………………………………………………………………………………………………………………..1011
P/S Pump and A/C Compressor (If Equipped) Drive Belt Removal and Installation………………………………………………………………………………………………………………………………1011
Steering Rack Boot Check……………………………………………………………………………………………………………………………………………………………………………..1012
Tie-Rod End Boot Check……………………………………………………………………………………………………………………………………………………………………………….1012
Tie-Rod End Removal and Installation…………………………………………………………………………………………………………………………………………………………………..1012
Tie-Rod End Ball Joint Inspection……………………………………………………………………………………………………………………………………………………………………..1013
P/S Gear Case Assembly Components……………………………………………………………………………………………………………………………………………………………………..1014
P/S Gear Case Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………………1015
Steering Gear Case Mount Bushing Removal and Installation………………………………………………………………………………………………………………………………………………..1016
Steering Gear Case Mount Bushing Inspection…………………………………………………………………………………………………………………………………………………………….1016
Rack Boot / Tie-Rod Removal and Installation……………………………………………………………………………………………………………………………………………………………1017
P/S Hose / Pipe Components……………………………………………………………………………………………………………………………………………………………………………1018
P/S Pump Removal and Installation……………………………………………………………………………………………………………………………………………………………………..1018
P/S Pump Components………………………………………………………………………………………………………………………………………………………………………………….1019
P/S Pump Disassembly and Assembly……………………………………………………………………………………………………………………………………………………………………..1019
P/S Pump Inspection………………………………………………………………………………………………………………………………………………………………………………….1022
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1022
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1022
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1023
Recommended Service Material………………………………………………………………………………………………………………………………………………………………………….1023
Special Tool………………………………………………………………………………………………………………………………………………………………………………………..1023
HVAC………………………………………………………………………………………………………………………………………………………………………………………………………….1025
Precautions………………………………………………………………………………………………………………………………………………………………………………………………..1028
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1028
Precautions for HVAC…………………………………………………………………………………………………………………………………………………………………………………1028
Heater and Ventilation………………………………………………………………………………………………………………………………………………………………………………………1029
General Description……………………………………………………………………………………………………………………………………………………………………………………..1029
Heater and Ventilation Construction……………………………………………………………………………………………………………………………………………………………………1029
Body Ventilation Construction…………………………………………………………………………………………………………………………………………………………………………1030
On-Board Diagnostic System Description (for Vehicle without A/C)………………………………………………………………………………………………………………………………………….1030
HVAC Control System Description (for Vehicle without A/C)………………………………………………………………………………………………………………………………………………..1031
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1031
Heater and Ventilation Wiring Circuit Diagram…………………………………………………………………………………………………………………………………………………………..1031
Electronic Control Input / Output Table (for Vehicle without A/C)…………………………………………………………………………………………………………………………………………1031
Electronic Components Location for Heater (for Vehicle without A/C)……………………………………………………………………………………………………………………………………….1032
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1033
Heater and Ventilation System Check……………………………………………………………………………………………………………………………………………………………………1033
Visual Inspection……………………………………………………………………………………………………………………………………………………………………………………1035
DTC Check…………………………………………………………………………………………………………………………………………………………………………………………..1035
DTC Clearance……………………………………………………………………………………………………………………………………………………………………………………….1035
DTC Table…………………………………………………………………………………………………………………………………………………………………………………………..1035
Fail-Safe Table……………………………………………………………………………………………………………………………………………………………………………………..1035
Scan Tool Data………………………………………………………………………………………………………………………………………………………………………………………1035
Heater and Ventilation Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….1036
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1037
Blower Unit and Heater Unit Components…………………………………………………………………………………………………………………………………………………………………1037
HVAC Unit Removal and Installation (for Vehicle without A/C)……………………………………………………………………………………………………………………………………………..1037
HVAC Air Filter Removal and Installation (for Vehicle without A/C)………………………………………………………………………………………………………………………………………..1037
HVAC Air Filter Inspection (for Vehicle without A/C)…………………………………………………………………………………………………………………………………………………….1037
Blower Motor Removal and Installation………………………………………………………………………………………………………………………………………………………………….1037
Blower Motor Inspection………………………………………………………………………………………………………………………………………………………………………………1037
Blower Motor Controller Removal and Installation………………………………………………………………………………………………………………………………………………………..1038
Blower Motor Controller Inspection…………………………………………………………………………………………………………………………………………………………………….1038
Blower Motor Relay Inspection…………………………………………………………………………………………………………………………………………………………………………1039
Heater Core Removal and Installation…………………………………………………………………………………………………………………………………………………………………..1039
HVAC Control Module Removal and Installation……………………………………………………………………………………………………………………………………………………………1039
HVAC Control Module and Its Circuits Inspection (for Vehicle without A/C)………………………………………………………………………………………………………………………………….1039
Air Flow Control Actuator Removal and Installation………………………………………………………………………………………………………………………………………………………1040
Air Flow Control Actuator Inspection…………………………………………………………………………………………………………………………………………………………………..1040
Temperature Control Actuator Removal and Installation……………………………………………………………………………………………………………………………………………………1041
Temperature Control Actuator Inspection………………………………………………………………………………………………………………………………………………………………..1041
Air Intake Control Actuator Removal and Installation…………………………………………………………………………………………………………………………………………………….1042
Air Intake Control Actuator Inspection…………………………………………………………………………………………………………………………………………………………………1042
Actuator Linkage Inspection…………………………………………………………………………………………………………………………………………………………………………..1043
Center Ventilation Louver Removal and Installation………………………………………………………………………………………………………………………………………………………1043
Side Ventilation Louver Removal and Installation………………………………………………………………………………………………………………………………………………………..1043
Rear Duct Components…………………………………………………………………………………………………………………………………………………………………………………1044
Rear Duct Removal and Installation…………………………………………………………………………………………………………………………………………………………………….1044
Air Conditioning System……………………………………………………………………………………………………………………………………………………………………………………..1045
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1045
A/C System Caution…………………………………………………………………………………………………………………………………………………………………………………..1045
Precautions on Servicing A/C System……………………………………………………………………………………………………………………………………………………………………1045
Precautions in Diagnosing Trouble……………………………………………………………………………………………………………………………………………………………………..1045
Precautions on Handling Refrigerant HFC-134a (R-134a)……………………………………………………………………………………………………………………………………………………1045
Precautions on Servicing Refrigerant Line………………………………………………………………………………………………………………………………………………………………1046
Precautions on Refrigerant Recovery……………………………………………………………………………………………………………………………………………………………………1046
Precautions on Refrigerant Charge……………………………………………………………………………………………………………………………………………………………………..1046
Precautions on Replenishing Compressor Oil……………………………………………………………………………………………………………………………………………………………..1047
Precautions on Servicing Compressor Assembly……………………………………………………………………………………………………………………………………………………………1047
General Description……………………………………………………………………………………………………………………………………………………………………………………..1048
AUTO A/C System Description…………………………………………………………………………………………………………………………………………………………………………..1048
HVAC Control System Description……………………………………………………………………………………………………………………………………………………………………….1048
Auto A/C Electronic Control Input / Output Table………………………………………………………………………………………………………………………………………………………..1048
HVAC Control Module Operation Description………………………………………………………………………………………………………………………………………………………………1049
A/C Refrigerant Type Description………………………………………………………………………………………………………………………………………………………………………1049
Sub-Cool A/C System Description……………………………………………………………………………………………………………………………………………………………………….1050
A/C Evaporator Temperature Sensor Description…………………………………………………………………………………………………………………………………………………………..1051
On-Board Diagnostic System Description…………………………………………………………………………………………………………………………………………………………………1051
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1052
A/C System Wiring Circuit Diagram……………………………………………………………………………………………………………………………………………………………………..1052
Component Location………………………………………………………………………………………………………………………………………………………………………………………1053
Major Components of A/C System………………………………………………………………………………………………………………………………………………………………………..1053
A/C Control System Components Location…………………………………………………………………………………………………………………………………………………………………1054
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1055
Air Conditioning System Check…………………………………………………………………………………………………………………………………………………………………………1055
DTC Check…………………………………………………………………………………………………………………………………………………………………………………………..1057
DTC Clearance……………………………………………………………………………………………………………………………………………………………………………………….1058
DTC Table…………………………………………………………………………………………………………………………………………………………………………………………..1059
Fail-Safe Table……………………………………………………………………………………………………………………………………………………………………………………..1061
Scan Tool Data………………………………………………………………………………………………………………………………………………………………………………………1062
Visual Inspection……………………………………………………………………………………………………………………………………………………………………………………1064
A/C System Performance Inspection……………………………………………………………………………………………………………………………………………………………………..1064
A/C System Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………………….1070
Abnormal Noise Diagnosis……………………………………………………………………………………………………………………………………………………………………………..1072
Abnormal Noise Symptom Diagnosis of A/C System………………………………………………………………………………………………………………………………………………………….1072
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction……………………………………………………………………………………………………………………………………1074
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction…………………………………………………………………………………………………………………………….1075
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction…………………………………………………………………………………………………………………………………………………1077
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction…………………………………………………………………………………………………………………….1078
DTC B1512: Air Flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction……………………………………………………………………………………………………………………….1081
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction…………………………………………………………………………………………………………………………………….1084
DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction……………………………………………………………………………………………………………………………………….1087
DTC B1520: Temperature Selector and/or Its Circuit Malfunction……………………………………………………………………………………………………………………………………………1089
DTC B1521: Blower Speed Selector and/or Its Circuit Malfunction…………………………………………………………………………………………………………………………………………..1090
DTC B1530: Air Intake Control Actuator (Position Sensor) and/or Its Circuit Malfunction……………………………………………………………………………………………………………………..1091
DTC B1531: Air Intake Control Actuator and/or Its Circuit Malfunction……………………………………………………………………………………………………………………………………..1093
DTC B1546: A/C Refrigerant Pressure Malfunction…………………………………………………………………………………………………………………………………………………………1096
DTC B1551: Serial Communication Circuit Malfunction……………………………………………………………………………………………………………………………………………………..1097
DTC B1552: Serial Communication Circuit Malfunction……………………………………………………………………………………………………………………………………………………..1098
DTC B1553: CAN Communication Circuit Malfunction………………………………………………………………………………………………………………………………………………………..1099
DTC B1556: Camshaft Position (CMP) Sensor and/or Its Circuit Malfunction…………………………………………………………………………………………………………………………………..1099
DTC B1557: Wheel Speed Sensor and/or Its Circuit Malfunction……………………………………………………………………………………………………………………………………………..1099
DTC B1561: Engine Coolant Temperature Sensor and/or Its Circuit Malfunction………………………………………………………………………………………………………………………………..1100
DTC B1562: Outside Air Temperature Sensor and/or Its Circuit Malfunction…………………………………………………………………………………………………………………………………..1100
DTC B1563: A/C Refrigerant Pressure Sensor and/or Its Circuit Malfunction………………………………………………………………………………………………………………………………….1100
HVAC Control Module and Its Circuits Inspection…………………………………………………………………………………………………………………………………………………………1101
A/C System Inspection at ECM………………………………………………………………………………………………………………………………………………………………………….1103
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1104
Operation Procedure for Charging A/C with Refrigerant……………………………………………………………………………………………………………………………………………………1104
A/C Condenser Assembly On-Vehicle Inspection……………………………………………………………………………………………………………………………………………………………1108
A/C Condenser Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………………1108
Desiccant Removal and Installation…………………………………………………………………………………………………………………………………………………………………….1109
HVAC Air Filter Removal and Installation……………………………………………………………………………………………………………………………………………………………….1110
HVAC Air Filter Inspection……………………………………………………………………………………………………………………………………………………………………………1110
HVAC Unit Components…………………………………………………………………………………………………………………………………………………………………………………1111
HVAC Unit Removal and Installation…………………………………………………………………………………………………………………………………………………………………….1112
A/C Evaporator Removal and Installation………………………………………………………………………………………………………………………………………………………………..1113
A/C Evaporator Inspection…………………………………………………………………………………………………………………………………………………………………………….1113
A/C Evaporator Temperature Sensor Removal and Installation……………………………………………………………………………………………………………………………………………….1113
A/C Evaporator Temperature Sensor Inspection……………………………………………………………………………………………………………………………………………………………1115
Expansion Valve On-Vehicle Inspection………………………………………………………………………………………………………………………………………………………………….1115
Expansion Valve Removal and Installation……………………………………………………………………………………………………………………………………………………………….1115
A/C Refrigerant Pressure Sensor and Its Circuit Inspection……………………………………………………………………………………………………………………………………………….1116
A/C Refrigerant Pressure Sensor Removal and Installation…………………………………………………………………………………………………………………………………………………1116
Sunload Sensor Removal and Installation………………………………………………………………………………………………………………………………………………………………..1117
Sunload Sensor Inspection…………………………………………………………………………………………………………………………………………………………………………….1117
Inside Air Temperature Sensor Removal and Installation…………………………………………………………………………………………………………………………………………………..1118
Inside Air Temperature Sensor Inspection……………………………………………………………………………………………………………………………………………………………….1118
Outside Air Temperature Sensor Removal and Installation………………………………………………………………………………………………………………………………………………….1118
Outside Air Temperature Sensor Inspection………………………………………………………………………………………………………………………………………………………………1118
Air Flow Control Actuator Removal and Installation………………………………………………………………………………………………………………………………………………………1118
Air Flow Control Actuator Inspection…………………………………………………………………………………………………………………………………………………………………..1118
Air Intake Control Actuator Removal and Installation…………………………………………………………………………………………………………………………………………………….1118
Air Intake Control Actuator Inspection…………………………………………………………………………………………………………………………………………………………………1118
Temperature Control Actuator Removal and Installation……………………………………………………………………………………………………………………………………………………1118
Temperature Control Actuator Inspection………………………………………………………………………………………………………………………………………………………………..1118
HVAC Control Module Removal and Installation……………………………………………………………………………………………………………………………………………………………1118
A/C Compressor Drive Belt Inspection and Adjustment……………………………………………………………………………………………………………………………………………………..1118
A/C Compressor Drive Belt Removal and Installation………………………………………………………………………………………………………………………………………………………1118
A/C Compressor Relay Inspection……………………………………………………………………………………………………………………………………………………………………….1119
Compressor Assembly On-Vehicle Inspection………………………………………………………………………………………………………………………………………………………………1119
Compressor Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………………1119
Magnet Clutch Components……………………………………………………………………………………………………………………………………………………………………………..1119
Magnet Clutch Operating Check…………………………………………………………………………………………………………………………………………………………………………1119
Magnet Clutch Removal and Installation…………………………………………………………………………………………………………………………………………………………………1119
Relief Valve On-Vehicle Inspection…………………………………………………………………………………………………………………………………………………………………….1119
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1120
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1120
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1120
Recommended Service Material………………………………………………………………………………………………………………………………………………………………………….1120
Special Tool………………………………………………………………………………………………………………………………………………………………………………………..1120
Restraint……………………………………………………………………………………………………………………………………………………………………………………………………..1121
Precautions………………………………………………………………………………………………………………………………………………………………………………………………..1123
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1123
Precautions on Restraint……………………………………………………………………………………………………………………………………………………………………………..1123
Seat Belts…………………………………………………………………………………………………………………………………………………………………………………………………1124
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1124
Precautions on Service and Diagnosis of Seat Belt……………………………………………………………………………………………………………………………………………………….1124
General Description……………………………………………………………………………………………………………………………………………………………………………………..1124
Seat Belt Construction……………………………………………………………………………………………………………………………………………………………………………….1124
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1125
Repair and Inspection Required after Accident…………………………………………………………………………………………………………………………………………………………..1125
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1126
Front Seat Belt Components……………………………………………………………………………………………………………………………………………………………………………1126
Front Seat Belt Removal and Installation……………………………………………………………………………………………………………………………………………………………….1127
Front Seat Belt Inspection……………………………………………………………………………………………………………………………………………………………………………1128
Rear Seat Belt Components…………………………………………………………………………………………………………………………………………………………………………….1129
Rear Seat Belt Removal and Installation………………………………………………………………………………………………………………………………………………………………..1130
Rear Seat Belt Inspection…………………………………………………………………………………………………………………………………………………………………………….1130
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1130
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1130
Air Bag System……………………………………………………………………………………………………………………………………………………………………………………………..1131
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1131
Precautions on Service and Diagnosis of Air Bag System…………………………………………………………………………………………………………………………………………………..1131
Precautions on Handling and Storage of Air Bag System Components………………………………………………………………………………………………………………………………………….1132
Precautions on Disposal of Air Bag and Seat Belt Pretensioner…………………………………………………………………………………………………………………………………………….1135
General Description……………………………………………………………………………………………………………………………………………………………………………………..1136
Air Bag System Construction…………………………………………………………………………………………………………………………………………………………………………..1136
Air Bag System Input / Output Table……………………………………………………………………………………………………………………………………………………………………1137
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1138
Air Bag System Wiring Circuit Diagram………………………………………………………………………………………………………………………………………………………………….1138
Component Location………………………………………………………………………………………………………………………………………………………………………………………1141
Air Bag System Components, Wiring and Connectors Location………………………………………………………………………………………………………………………………………………..1141
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1142
Air Bag Diagnostic System Check……………………………………………………………………………………………………………………………………………………………………….1142
Air Bag Diagnostic System Check Flow…………………………………………………………………………………………………………………………………………………………………..1142
DTC Table…………………………………………………………………………………………………………………………………………………………………………………………..1144
DTC Check…………………………………………………………………………………………………………………………………………………………………………………………..1146
DTC Clearance……………………………………………………………………………………………………………………………………………………………………………………….1147
Scan Tool Data………………………………………………………………………………………………………………………………………………………………………………………1148
“AIR BAG” Warning Lamp Comes ON Steady…………………………………………………………………………………………………………………………………………………………………1148
“AIR BAG” Warning Lamp Does Not Come ON………………………………………………………………………………………………………………………………………………………………..1151
“AIR BAG” Warning Lamp Flashes………………………………………………………………………………………………………………………………………………………………………..1152
“AIR BAG” Warning Lamp Cannot Indicate Flashing Pattern of DTC (If Equipped with “AIR BAG” Monitor Coupler)……………………………………………………………………………………………………1153
DTC B1013: SDM fault…………………………………………………………………………………………………………………………………………………………………………………1154
DTC B1016: Power Source Voltage High…………………………………………………………………………………………………………………………………………………………………..1154
DTC B1017: Power Source Voltage Low……………………………………………………………………………………………………………………………………………………………………1156
DTC B1021: Air Bag Module Deployed…………………………………………………………………………………………………………………………………………………………………….1158
DTC B1031: Driver Air Bag Initiator Circuit Resistance High………………………………………………………………………………………………………………………………………………1159
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low……………………………………………………………………………………………………………………………………………….1163
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground………………………………………………………………………………………………………………………………………………1166
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit………………………………………………………………………………………………………………………………………..1169
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High……………………………………………………………………………………………………………………………………………1172
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low…………………………………………………………………………………………………………………………………………….1175
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground……………………………………………………………………………………………………………………………………………1178
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit……………………………………………………………………………………………………………………………………..1181
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High………………………………………………………………………………………………………………………..1184
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low…………………………………………………………………………………………………………………………1187
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground………………………………………………………………………………………………………………………..1190
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit………………………………………………………………………………………………………………….1193
DTC B1073 / B1077: Driver / Passenger Forward-Sensor Circuit Short to Ground……………………………………………………………………………………………………………………………….1196
DTC B1074 / B1078: Driver / Passenger Forward-Sensor Circuit Short to Power Circuit or Open………………………………………………………………………………………………………………….1198
DTC B1085: Wrong Side-Sensor ID……………………………………………………………………………………………………………………………………………………………………….1200
DTC B1086 / B1096: Left / Right Side-Sensor Performance Problem…………………………………………………………………………………………………………………………………………..1200
DTC B1087 / B1097: Left / Right Side-Sensor Communication Error…………………………………………………………………………………………………………………………………………..1200
DTC B1321 / B1325: Left / Right Side-Air Bag Initiator Circuit Resistance High……………………………………………………………………………………………………………………………..1202
DTC B1322 / B1326: Left / Right Side-Air Bag Initiator Circuit Resistance Low………………………………………………………………………………………………………………………………1206
DTC B1323 / B1327: Left / Right Side-Air Bag Initiator Circuit Short to Ground……………………………………………………………………………………………………………………………..1209
DTC B1324 / B1328: Left / Right Side-Air Bag Initiator Circuit Short to Power Circuit……………………………………………………………………………………………………………………….1212
DTC B1331 / B1335: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance High………………………………………………………………………………………………………………………1215
DTC B1332 / B1336: Left / Right Side Curtain-Air Bag Initiator Circuit Resistance Low……………………………………………………………………………………………………………………….1218
DTC B1333 / B1337: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Ground………………………………………………………………………………………………………………………1220
DTC B1334 / B1338: Left / Right Side Curtain-Air Bag Initiator Circuit Short to Power Circuit………………………………………………………………………………………………………………..1222
Inspection of Intermittent and Poor Connections…………………………………………………………………………………………………………………………………………………………1223
Repair and Inspection Required after Accident…………………………………………………………………………………………………………………………………………………………..1224
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1227
Disabling Air Bag System……………………………………………………………………………………………………………………………………………………………………………..1227
Enabling Air Bag System………………………………………………………………………………………………………………………………………………………………………………1228
SDM Removal and Installation………………………………………………………………………………………………………………………………………………………………………….1229
SDM Inspection………………………………………………………………………………………………………………………………………………………………………………………1230
Driver Air Bag (Inflator) Module Removal and Installation………………………………………………………………………………………………………………………………………………..1230
Driver Air Bag (Inflator) Module Inspection…………………………………………………………………………………………………………………………………………………………….1231
Passenger Air Bag (Inflator) Module Removal and Installation……………………………………………………………………………………………………………………………………………..1232
Passenger Air Bag (Inflator) Module Inspection………………………………………………………………………………………………………………………………………………………….1233
Side-Air Bag (Inflator) Module Removal and Installation………………………………………………………………………………………………………………………………………………….1234
Side-Air Bag (Inflator) Inspection…………………………………………………………………………………………………………………………………………………………………….1235
Side Curtain-Air Bag (Inflator) Module Removal and Installation…………………………………………………………………………………………………………………………………………..1236
Side Curtain-Air Bag (Inflator) Module Inspection……………………………………………………………………………………………………………………………………………………….1237
Forward-Sensor Removal and Installation………………………………………………………………………………………………………………………………………………………………..1238
Forward-Sensor Inspection…………………………………………………………………………………………………………………………………………………………………………….1239
Side-Sensor Removal and Installation…………………………………………………………………………………………………………………………………………………………………..1239
Side-Sensor Inspection……………………………………………………………………………………………………………………………………………………………………………….1240
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal…………………………………………………………………………………………………………………………………………….1241
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal……………………………………………………………………………………………………………………………1251
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1252
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1252
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1253
Use of Special Tools…………………………………………………………………………………………………………………………………………………………………………………1253
Recommended Service Material………………………………………………………………………………………………………………………………………………………………………….1254
Special Tool………………………………………………………………………………………………………………………………………………………………………………………..1254
Body, Cab and Accessories……………………………………………………………………………………………………………………………………………………………………………………….1257
Precautions………………………………………………………………………………………………………………………………………………………………………………………………..1263
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1263
Precautions on Body, Cab and Accessories……………………………………………………………………………………………………………………………………………………………….1263
Precautions for Body Service………………………………………………………………………………………………………………………………………………………………………….1263
Fastener Caution for Body Service……………………………………………………………………………………………………………………………………………………………………..1263
Wiring Systems……………………………………………………………………………………………………………………………………………………………………………………………..1264
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1264
Cautions in Body Electrical System Servicing……………………………………………………………………………………………………………………………………………………………1264
Precautions for Wiring System…………………………………………………………………………………………………………………………………………………………………………1264
General Description……………………………………………………………………………………………………………………………………………………………………………………..1265
Abbreviations……………………………………………………………………………………………………………………………………………………………………………………….1265
Wire / Connector Color Symbols………………………………………………………………………………………………………………………………………………………………………..1265
Symbols and Marks……………………………………………………………………………………………………………………………………………………………………………………1266
How to Read Connector Layout Diagram…………………………………………………………………………………………………………………………………………………………………..1268
How to Read Connector Codes and Terminal Nos……………………………………………………………………………………………………………………………………………………………1269
How to Read Ground Point……………………………………………………………………………………………………………………………………………………………………………..1272
How to Read Power Supply Diagram………………………………………………………………………………………………………………………………………………………………………1273
How to Read System Circuit Diagram…………………………………………………………………………………………………………………………………………………………………….1274
Harness Routing and Connector Layout Diagram……………………………………………………………………………………………………………………………………………………………….1276
Connector Layout Diagram……………………………………………………………………………………………………………………………………………………………………………..1276
Engine Compartment…………………………………………………………………………………………………………………………………………………………………………………..1276
Instrument Panel…………………………………………………………………………………………………………………………………………………………………………………….1294
Door, Roof………………………………………………………………………………………………………………………………………………………………………………………….1301
Floor………………………………………………………………………………………………………………………………………………………………………………………………1305
Rear……………………………………………………………………………………………………………………………………………………………………………………………….1311
Ground Point……………………………………………………………………………………………………………………………………………………………………………………………1312
Ground (earth) Point…………………………………………………………………………………………………………………………………………………………………………………1312
Power Supply Diagram…………………………………………………………………………………………………………………………………………………………………………………….1314
Power Supply Diagram…………………………………………………………………………………………………………………………………………………………………………………1314
Fuses and the Protected Parts…………………………………………………………………………………………………………………………………………………………………………1317
Fuses in Battery Fuse Box, Fuse Box No.1 (Petrol)……………………………………………………………………………………………………………………………………………………….1317
Fuses in Battery Fuse Box, Fuse Box No.1 (DSL)………………………………………………………………………………………………………………………………………………………….1318
Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box (Petrol)……………………………………………………………………………………………………………………….1319
Fuse Box No.2 (In Power Integration No.1, Power Integration No.2), Relay Box No.1, Relay Box No.2 (DSL)……………………………………………………………………………………………………….1320
Fuse Box No.3 (In J/B)……………………………………………………………………………………………………………………………………………………………………………….1322
Junction Block (J/B) Connector / Fuse Layout……………………………………………………………………………………………………………………………………………………………1324
Junction Block Inner Circuit (Overview)………………………………………………………………………………………………………………………………………………………………..1325
Junction Block Inner Circuit (Detail)………………………………………………………………………………………………………………………………………………………………….1326
System Circuit Diagram…………………………………………………………………………………………………………………………………………………………………………………..1330
System Circuit Diagram……………………………………………………………………………………………………………………………………………………………………………….1330
A-1 Cranking System Circuit Diagram……………………………………………………………………………………………………………………………………………………………………1331
A-2 Charging System Circuit Diagram……………………………………………………………………………………………………………………………………………………………………1332
A-3 Ignition System Circuit Diagram (M16A)……………………………………………………………………………………………………………………………………………………………..1333
A-3 Ignition System Circuit Diagram (J20A)……………………………………………………………………………………………………………………………………………………………..1334
A-3 Ignition System Circuit Diagram (H27A)……………………………………………………………………………………………………………………………………………………………..1335
A-4 Cooling System Circuit Diagram (Petrol)…………………………………………………………………………………………………………………………………………………………….1337
A-4 Cooling System Circuit Diagram (DSL)……………………………………………………………………………………………………………………………………………………………….1338
A-5 Engine and A/C Control System Circuit Diagram (M16A)…………………………………………………………………………………………………………………………………………………1339
A-5 Engine and A/C Control System Circuit Diagram (J20A)…………………………………………………………………………………………………………………………………………………1344
A-5 Engine and A/C Control System Circuit Diagram (H27A)…………………………………………………………………………………………………………………………………………………1349
A-5 Engine and A/C Control System Circuit Diagram (DSL)………………………………………………………………………………………………………………………………………………….1354
A-6 A/T Control System Circuit Diagram…………………………………………………………………………………………………………………………………………………………………1359
A-7 Immobilizer System Circuit Diagram…………………………………………………………………………………………………………………………………………………………………1362
A-8 Body Control System Circuit Diagram………………………………………………………………………………………………………………………………………………………………..1363
A-10 4WD Control System Circuit Diagram………………………………………………………………………………………………………………………………………………………………..1368
B-1 Windshield Wiper and Washer Circuit Diagram…………………………………………………………………………………………………………………………………………………………1370
B-2 Rear Wiper and Washer Circuit Diagram………………………………………………………………………………………………………………………………………………………………1371
B-3 Rear Defogger Circuit Diagram……………………………………………………………………………………………………………………………………………………………………..1372
B-4 Power Window Circuit Diagram………………………………………………………………………………………………………………………………………………………………………1373
B-5 Power Door Lock Circuit Diagram……………………………………………………………………………………………………………………………………………………………………1375
B-6 Power Mirror Circuit Diagram………………………………………………………………………………………………………………………………………………………………………1377
B-7 Horn Circuit Diagram……………………………………………………………………………………………………………………………………………………………………………..1378
B-8 Seat Heater Circuit Diagram……………………………………………………………………………………………………………………………………………………………………….1379
B-9 Smart Key System Circuit Diagram…………………………………………………………………………………………………………………………………………………………………..1380
B-10 Sliding Roof Circuit Diagram……………………………………………………………………………………………………………………………………………………………………..1381
B-11 Headlight Cleaner Circuit Diagram…………………………………………………………………………………………………………………………………………………………………1382
C-1 Combination Meter Circuit Diagram………………………………………………………………………………………………………………………………………………………………….1383
D-1 Headlight System Circuit Diagram (One bulb type)…………………………………………………………………………………………………………………………………………………….1385
D-1 Headlight System Circuit Diagram (With Projector light)………………………………………………………………………………………………………………………………………………1386
D-1 Headlight System Circuit Diagram (With Discharge bulb)……………………………………………………………………………………………………………………………………………….1387
D-2 Position, Tail and Licence Plate Light System Circuit Diagram…………………………………………………………………………………………………………………………………………1388
D-3 Front Fog Light System Circuit Diagram……………………………………………………………………………………………………………………………………………………………..1389
D-4 Illumination Light System Circuit Diagram…………………………………………………………………………………………………………………………………………………………..1390
D-5 Interior Light System Circuit Diagram………………………………………………………………………………………………………………………………………………………………1391
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram…………………………………………………………………………………………………………………………………………..1392
D-7 Brake Light System Circuit Diagram…………………………………………………………………………………………………………………………………………………………………1394
D-8 Back-Up Light System Circuit Diagram……………………………………………………………………………………………………………………………………………………………….1395
D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling)………………………………………………………………………………………………………………………………………1396
D-9 Headlight Beam Leveling System Circuit Diagram (Auto Leveling)………………………………………………………………………………………………………………………………………..1397
D-10 Rear Fog Light Circuit Diagram……………………………………………………………………………………………………………………………………………………………………1398
E-2 Auto A/C System Circuit Diagram……………………………………………………………………………………………………………………………………………………………………1399
F-1 Air-Bag System Circuit Diagram (4ch)……………………………………………………………………………………………………………………………………………………………….1401
F-1 Air-Bag System Circuit Diagram (8ch)……………………………………………………………………………………………………………………………………………………………….1402
F-2 Anti-Lock Brake System Circuit Diagram……………………………………………………………………………………………………………………………………………………………..1404
F-3 Electronic Stability Program System Circuit Diagram………………………………………………………………………………………………………………………………………………….1406
G-1 Audio System Circuit Diagram………………………………………………………………………………………………………………………………………………………………………1408
G-2 Multi Information Display / Accessory Socket System Circuit Diagram……………………………………………………………………………………………………………………………………1409
G-4 Navigation System Circuit Diagram………………………………………………………………………………………………………………………………………………………………….1410
List of Connectors………………………………………………………………………………………………………………………………………………………………………………………1411
List of Connectors…………………………………………………………………………………………………………………………………………………………………………………..1411
B Connector…………………………………………………………………………………………………………………………………………………………………………………………1411
C Connector…………………………………………………………………………………………………………………………………………………………………………………………1411
D Connector…………………………………………………………………………………………………………………………………………………………………………………………1414
E Connector…………………………………………………………………………………………………………………………………………………………………………………………1414
F Connector…………………………………………………………………………………………………………………………………………………………………………………………1417
G Connector…………………………………………………………………………………………………………………………………………………………………………………………1417
J Connector…………………………………………………………………………………………………………………………………………………………………………………………1420
K Connector…………………………………………………………………………………………………………………………………………………………………………………………1421
L Connector…………………………………………………………………………………………………………………………………………………………………………………………1422
O Connector…………………………………………………………………………………………………………………………………………………………………………………………1424
Q Connector…………………………………………………………………………………………………………………………………………………………………………………………1424
R Connector…………………………………………………………………………………………………………………………………………………………………………………………1424
Lighting Systems……………………………………………………………………………………………………………………………………………………………………………………………1425
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1425
Precautions for Discharge Headlight Service (If Equipped)………………………………………………………………………………………………………………………………………………..1425
Precautions in Diagnosing Troubles (Vehicle Equipped with Auto Leveling Headlight System)……………………………………………………………………………………………………………………1425
General Description……………………………………………………………………………………………………………………………………………………………………………………..1426
Discharge Headlight Description (If Equipped)…………………………………………………………………………………………………………………………………………………………..1426
Auto Leveling Headlight System Description (If Equipped)…………………………………………………………………………………………………………………………………………………1427
Auto-On Headlight System Description (If Equipped)………………………………………………………………………………………………………………………………………………………1429
D.R.L. System Description (If Equipped)………………………………………………………………………………………………………………………………………………………………..1430
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1430
Headlight Auto Leveling System Wiring Circuit Diagram……………………………………………………………………………………………………………………………………………………1430
Component Location………………………………………………………………………………………………………………………………………………………………………………………1431
Lighting System Components Location……………………………………………………………………………………………………………………………………………………………………1431
Interior Light System Location………………………………………………………………………………………………………………………………………………………………………..1432
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1432
Self-Diagnosis Function for Auto Leveling Headlight System……………………………………………………………………………………………………………………………………………….1432
Headlight Leveling Warning Light Check…………………………………………………………………………………………………………………………………………………………………1432
Headlight Symptom Diagnosis (Vehicle Equipped with Discharge Headlight)……………………………………………………………………………………………………………………………………1433
Headlight Symptom Diagnosis (Vehicle Not Equipped with Discharge Headlight)………………………………………………………………………………………………………………………………..1433
Auto-On Headlight System Symptom Diagnosis (If Equipped)…………………………………………………………………………………………………………………………………………………1434
DRL System Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………………..1434
Headlight Auto Leveling System Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………1435
Headlight Manual Leveling System Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………….1435
Turn Signal and Hazard Warning Light Symptom Diagnosis…………………………………………………………………………………………………………………………………………………..1436
Clearance, Tail and License Plate Light Symptom Diagnosis………………………………………………………………………………………………………………………………………………..1436
Back-Up Light Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………………….1437
Stop (Brake) Lamp Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………………1437
Front Fog Light (If Equipped) Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………1437
Rear Fog Light Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………………………….1437
Illumination Cancel System Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………….1438
Interior Light Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………………1438
Auto-On Headlight Operation Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………….1438
DRL Operation Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………………………1439
Inspection of Headlight Leveling Control Module and Its Circuit (Vehicle Equipped with Auto Leveling Headlight System)………………………………………………………………………………………….1439
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1441
Headlight Housing Removal and Installation……………………………………………………………………………………………………………………………………………………………..1441
Headlight Bulb Replacement……………………………………………………………………………………………………………………………………………………………………………1441
Ballast Removal and Installation………………………………………………………………………………………………………………………………………………………………………1443
Igniter Removal and Installation………………………………………………………………………………………………………………………………………………………………………1443
Headlight Aiming Adjustment with Screen………………………………………………………………………………………………………………………………………………………………..1444
Headlight Switch (in Lighting Switch) Removal and Installation……………………………………………………………………………………………………………………………………………1446
Headlight Switch (in Lighting Switch) Inspection………………………………………………………………………………………………………………………………………………………..1446
Hazard Warning Switch Removal and Installation………………………………………………………………………………………………………………………………………………………….1447
Hazard Warning Switch Inspection………………………………………………………………………………………………………………………………………………………………………1447
Stop (Brake) Lamp Switch Inspection……………………………………………………………………………………………………………………………………………………………………1447
Turn Signal Light Switch (in Lighting Switch) Removal and Installation…………………………………………………………………………………………………………………………………….1447
Turn Signal Light Switch (in Lighting Switch) Inspection…………………………………………………………………………………………………………………………………………………1448
Turn Signal and Hazard Warning Relay Removal and Installation…………………………………………………………………………………………………………………………………………….1448
Turn Signal and Hazard Warning Relay Inspection…………………………………………………………………………………………………………………………………………………………1448
License Lamp Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………….1449
Front Fog Light Assembly Removal and Installation (If Equipped)…………………………………………………………………………………………………………………………………………..1449
Front Fog Light Bulb Replacement (If Equipped)………………………………………………………………………………………………………………………………………………………….1449
Front Fog Light Switch Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………………1450
Front Fog Light Relay Inspection (If Equipped)………………………………………………………………………………………………………………………………………………………….1450
Front Fog Light Aiming Adjustment with Screen (If Equipped)………………………………………………………………………………………………………………………………………………1451
Headlight Manual Leveling Switch (If Equipped) Inspection………………………………………………………………………………………………………………………………………………..1452
Headlight Leveling Actuator Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………….1452
Rear Fog Light Switch Inspection (If Equipped)………………………………………………………………………………………………………………………………………………………….1453
Height Sensor Removal and Installation (If Equipped)…………………………………………………………………………………………………………………………………………………….1453
Height Sensor and Its Circuit Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………..1454
Leveling Control Module Removal and Installation (If Equipped)……………………………………………………………………………………………………………………………………………1455
Initialization of Auto Leveling Headlight System………………………………………………………………………………………………………………………………………………………..1455
Illumination Cancel Switch (If Equipped) Inspection……………………………………………………………………………………………………………………………………………………..1456
Auto-On Headlight Sensor Inspection (If Equipped)……………………………………………………………………………………………………………………………………………………….1456
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1456
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1456
Instrumentation / Driver Info. / Horn…………………………………………………………………………………………………………………………………………………………………………1457
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1457
Precautions in Diagnosing Troubles for Combination Meter…………………………………………………………………………………………………………………………………………………1457
General Description……………………………………………………………………………………………………………………………………………………………………………………..1457
CAN Communication Data of Combination Meter…………………………………………………………………………………………………………………………………………………………….1457
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1458
Combination Meter Circuit Diagram……………………………………………………………………………………………………………………………………………………………………..1458
Component Location………………………………………………………………………………………………………………………………………………………………………………………1459
Audio System Component Location……………………………………………………………………………………………………………………………………………………………………….1459
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1460
Speedometer Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………………1460
Tacho meter Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………………1460
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis…………………………………………………………………………………………………………………………………………………1460
Fuel Meter Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………………….1460
Low Fuel Warning Light Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….1461
Oil Pressure Warning Light Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………1461
Brake and Parking Brake Warning Light Symptom Diagnosis………………………………………………………………………………………………………………………………………………….1462
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)…………………………………………………………………………………………………………………………………………………1462
Illumination Indicator Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….1463
Headlight Auto Leveling Indicator Symptom Diagnosis (If Equipped)…………………………………………………………………………………………………………………………………………1463
A/T Power Mode Indicator Symptom Diagnosis (A/T Model Only)………………………………………………………………………………………………………………………………………………1464
A/T Shift Position Indicator (A/T Model Only) Symptom Diagnosis…………………………………………………………………………………………………………………………………………..1464
Charge Warning Light Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………1464
Main Beam (High Beam) Indicator Symptom Diagnosis……………………………………………………………………………………………………………………………………………………….1465
Warning Buzzer Circuit Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….1465
Cigarette Lighter Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………….1465
Horn Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………………………….1466
Information Display Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………..1466
Clock Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………………………………….1467
Audio System Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………………1467
Remote Audio Control Switch Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………………1468
Navigation Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………………..1468
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1469
Ignition Switch Removal and Installation……………………………………………………………………………………………………………………………………………………………….1469
Ignition Switch Inspection……………………………………………………………………………………………………………………………………………………………………………1469
Combination Meter Removal and Installation……………………………………………………………………………………………………………………………………………………………..1470
Fuel Level Sensor Removal and Installation……………………………………………………………………………………………………………………………………………………………..1470
Fuel Level Sensor Inspection………………………………………………………………………………………………………………………………………………………………………….1470
Oil Pressure Switch Removal and Installation……………………………………………………………………………………………………………………………………………………………1471
Oil Pressure Switch Inspection………………………………………………………………………………………………………………………………………………………………………..1471
Engine Coolant Temperature (ECT) Sensor Inspection………………………………………………………………………………………………………………………………………………………1472
Brake Fluid Level Switch Inspection……………………………………………………………………………………………………………………………………………………………………1472
Parking Brake Switch Inspection……………………………………………………………………………………………………………………………………………………………………….1472
Door Switch (Front / Rear / Rear End Door) Inspection……………………………………………………………………………………………………………………………………………………1472
Outside Air Temperature Sensor Removal and Installation (If Equipped)……………………………………………………………………………………………………………………………………..1472
Outside Air Temperature Sensor Inspection (If Equipped)………………………………………………………………………………………………………………………………………………….1473
Instrument Panel Removal and Installation………………………………………………………………………………………………………………………………………………………………1473
Information Display (Clock) Removal and Installation…………………………………………………………………………………………………………………………………………………….1474
Audio Unit Removal and Installation……………………………………………………………………………………………………………………………………………………………………1475
Front Speaker Removal and Installation…………………………………………………………………………………………………………………………………………………………………1475
Rear Speaker Removal and Installation (5 Door Model)…………………………………………………………………………………………………………………………………………………….1475
Rear Speaker Removal and Installation (3 Door Model)…………………………………………………………………………………………………………………………………………………….1476
GPS Antenna Removal and Installation (If Equipped)………………………………………………………………………………………………………………………………………………………1476
Horn Removal and Installation…………………………………………………………………………………………………………………………………………………………………………1476
Horn Inspection……………………………………………………………………………………………………………………………………………………………………………………..1477
Horn Relay Inspection………………………………………………………………………………………………………………………………………………………………………………..1477
Antenna Base Removal and Installation………………………………………………………………………………………………………………………………………………………………….1477
Remote Audio Control Switch Removal and Installation…………………………………………………………………………………………………………………………………………………….1478
Remote Audio Control Switch Inspection…………………………………………………………………………………………………………………………………………………………………1478
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1479
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1479
Wipers / Washers……………………………………………………………………………………………………………………………………………………………………………………………1480
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1480
Front Wiper and Washer Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….1480
Rear Wiper and Washer Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………1480
Headlight Washer Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………………………..1481
Headlight Washer Operation Inspection………………………………………………………………………………………………………………………………………………………………….1481
Inspection of Headlight Washer Control Module and Its Circuit…………………………………………………………………………………………………………………………………………….1482
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1483
Wipers and Washers Components…………………………………………………………………………………………………………………………………………………………………………1483
Washer Tank and Washer Pump Removal and Installation…………………………………………………………………………………………………………………………………………………….1484
Washer Pump Inspection……………………………………………………………………………………………………………………………………………………………………………….1484
Windshield Wiper Removal and Installation………………………………………………………………………………………………………………………………………………………………1485
Windshield Wiper Motor Inspection……………………………………………………………………………………………………………………………………………………………………..1486
Rear Wiper Removal and Installation (If Equipped)……………………………………………………………………………………………………………………………………………………….1487
Rear Wiper Motor Inspection (If Equipped)………………………………………………………………………………………………………………………………………………………………1488
Windshield Wiper and Washer Switch Removal and Installation………………………………………………………………………………………………………………………………………………1489
Windshield Wiper and Washer Switch Inspection…………………………………………………………………………………………………………………………………………………………..1490
Rear Wiper and Washer Switch Removal and Installation……………………………………………………………………………………………………………………………………………………1491
Rear Wiper and Washer Switch Inspection………………………………………………………………………………………………………………………………………………………………..1491
Rear Wiper Relay Removal and Installation………………………………………………………………………………………………………………………………………………………………1491
Rear Wiper Relay Inspection…………………………………………………………………………………………………………………………………………………………………………..1492
Headlight Washer Switch Inspection (If Equipped)………………………………………………………………………………………………………………………………………………………..1492
Headlight Washer Pump Removal and Installation (If Equipped)……………………………………………………………………………………………………………………………………………..1492
Headlight Washer Nozzle Removal and Installation (If Equipped)……………………………………………………………………………………………………………………………………………1492
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1493
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1493
Glass / Windows / Mirrors……………………………………………………………………………………………………………………………………………………………………………………1494
General Description……………………………………………………………………………………………………………………………………………………………………………………..1494
Rear End Door Window Defogger System Description………………………………………………………………………………………………………………………………………………………..1494
Windshield Construction………………………………………………………………………………………………………………………………………………………………………………1494
Rear Quarter Window Construction………………………………………………………………………………………………………………………………………………………………………1495
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1496
Rear End door Window Defogger Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………1496
Power Window Control System Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………..1497
Power Door Mirror Control System Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………….1497
Door Mirror Heater Symptom Diagnosis (If Equipped)………………………………………………………………………………………………………………………………………………………1497
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1498
Windshield Removal and Installation……………………………………………………………………………………………………………………………………………………………………1498
Rear Quarter Window Removal and Installation……………………………………………………………………………………………………………………………………………………………1501
Front Door Window Components………………………………………………………………………………………………………………………………………………………………………….1506
Front Door Glass Removal and Installation………………………………………………………………………………………………………………………………………………………………1507
Front Door Window Regulator Removal and Installation…………………………………………………………………………………………………………………………………………………….1508
Front Door Window Regulator Inspection…………………………………………………………………………………………………………………………………………………………………1508
Rear Door Window Components…………………………………………………………………………………………………………………………………………………………………………..1509
Rear Door Glass Removal and Installation……………………………………………………………………………………………………………………………………………………………….1509
Rear Door Window Regulator Removal and Installation……………………………………………………………………………………………………………………………………………………..1511
Rear Door Window Regulator Inspection………………………………………………………………………………………………………………………………………………………………….1511
Rear End Door Window Components……………………………………………………………………………………………………………………………………………………………………….1511
Rear End Door Glass Removal and Installation……………………………………………………………………………………………………………………………………………………………1512
Rear End Door Window Defogger Relay Inspection………………………………………………………………………………………………………………………………………………………….1512
Rear End Door Window Defogger Wire Inspection…………………………………………………………………………………………………………………………………………………………..1513
Rear End Door Window Defogger Wire Repair………………………………………………………………………………………………………………………………………………………………1513
Power Window Main Switch Inspection……………………………………………………………………………………………………………………………………………………………………1514
Power Window Sub Switch Inspection…………………………………………………………………………………………………………………………………………………………………….1515
Door Mirror Components……………………………………………………………………………………………………………………………………………………………………………….1516
Door Mirror Removal and Installation…………………………………………………………………………………………………………………………………………………………………..1516
Power Door Mirror Switch Inspection (If Equipped)……………………………………………………………………………………………………………………………………………………….1516
Power Door Mirror Actuator Inspection (If Equipped)……………………………………………………………………………………………………………………………………………………..1517
Door Mirror Heater Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………………….1517
Door Mirror Heater Relay Inspection (If Equipped)……………………………………………………………………………………………………………………………………………………….1517
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1518
Recommended Service Material………………………………………………………………………………………………………………………………………………………………………….1518
Security and Locks………………………………………………………………………………………………………………………………………………………………………………………….1519
General Description……………………………………………………………………………………………………………………………………………………………………………………..1519
Key Coding Construction………………………………………………………………………………………………………………………………………………………………………………1519
Component Location………………………………………………………………………………………………………………………………………………………………………………………1519
Power Door Lock and Keyless Entry System Component Location………………………………………………………………………………………………………………………………………………1519
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1520
Power Door Lock System Symptom Diagnosis……………………………………………………………………………………………………………………………………………………………….1520
Power Door Lock System Operation Inspection…………………………………………………………………………………………………………………………………………………………….1520
Keyless Entry System Symptom Diagnosis (If Equipped)…………………………………………………………………………………………………………………………………………………….1521
Keyless Entry System Operation Inspection………………………………………………………………………………………………………………………………………………………………1522
Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)…………………………………………………………………………………………………………………………………1522
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1522
Front Door Lock Assembly Components……………………………………………………………………………………………………………………………………………………………………1522
Front Door Lock Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………….1523
Front Door Lock Assembly Inspection……………………………………………………………………………………………………………………………………………………………………1524
Power Door Lock Switch Inspection……………………………………………………………………………………………………………………………………………………………………..1525
Door Key Cylinder Switch Inspection……………………………………………………………………………………………………………………………………………………………………1525
Power Door Lock Actuator Inspection (If Equipped)……………………………………………………………………………………………………………………………………………………….1525
Rear Door Lock Assembly Components…………………………………………………………………………………………………………………………………………………………………….1527
Rear Door Lock Assembly Removal and Installation………………………………………………………………………………………………………………………………………………………..1528
Rear Door Lock Assembly Inspection…………………………………………………………………………………………………………………………………………………………………….1528
Rear End Door Lock Assembly Components…………………………………………………………………………………………………………………………………………………………………1529
Rear End Door Lock Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………….1529
Rear End Door Lock Assembly Inspection…………………………………………………………………………………………………………………………………………………………………1530
Replacement of Transmitter Battery…………………………………………………………………………………………………………………………………………………………………….1530
Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System)…………………………………………………………………………………………………………………1531
Keyless Entry Receiver Removal and Installation…………………………………………………………………………………………………………………………………………………………1531
Keyless Entry Receiver and Its Circuit Inspection……………………………………………………………………………………………………………………………………………………….1532
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1533
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1533
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1533
Recommended Service Material………………………………………………………………………………………………………………………………………………………………………….1533
Seats……………………………………………………………………………………………………………………………………………………………………………………………………..1534
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1534
Front Seat Heater Symptom Diagnosis (If Equipped)……………………………………………………………………………………………………………………………………………………….1534
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1534
Front Seat Components………………………………………………………………………………………………………………………………………………………………………………..1534
Front Seat Removal and Installation……………………………………………………………………………………………………………………………………………………………………1535
Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)………………………………………………………………………………………………………………………………1535
Front Seat Heater Wire Inspection (If Equipped)…………………………………………………………………………………………………………………………………………………………1535
Rear Seat Components…………………………………………………………………………………………………………………………………………………………………………………1536
Rear Seat Removal and Installation…………………………………………………………………………………………………………………………………………………………………….1536
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1536
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1536
Interior Trim………………………………………………………………………………………………………………………………………………………………………………………………1537
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1537
Floor Carpet Removal and Installation………………………………………………………………………………………………………………………………………………………………….1537
Head Lining Removal and Installation…………………………………………………………………………………………………………………………………………………………………..1537
Console Box Components……………………………………………………………………………………………………………………………………………………………………………….1539
Sun Roof / T-Top / Convertible Top……………………………………………………………………………………………………………………………………………………………………………1540
General Description……………………………………………………………………………………………………………………………………………………………………………………..1540
Power Sun Roof System Description……………………………………………………………………………………………………………………………………………………………………..1540
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1540
Power Sun Roof System Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………..1540
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1540
Sun Roof Glass Components…………………………………………………………………………………………………………………………………………………………………………….1540
Sun Roof Glass Removal and Installation………………………………………………………………………………………………………………………………………………………………..1541
Sun Roof Glass Adjustment…………………………………………………………………………………………………………………………………………………………………………….1541
Sun Roof Switch Inspection……………………………………………………………………………………………………………………………………………………………………………1541
Sun Roof Motor Removal and Installation………………………………………………………………………………………………………………………………………………………………..1542
Sun Roof System Circuit and Motor Inspection……………………………………………………………………………………………………………………………………………………………1542
Sun Roof Assembly Components………………………………………………………………………………………………………………………………………………………………………….1543
Sun Roof Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………………..1544
Sun Roof Assembly Disassembly and Reassembly……………………………………………………………………………………………………………………………………………………………1545
Hood / Fenders / Doors………………………………………………………………………………………………………………………………………………………………………………………1546
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1546
Hood Removal and Installation…………………………………………………………………………………………………………………………………………………………………………1546
Hood Inspection and Adjustment………………………………………………………………………………………………………………………………………………………………………..1546
Front Fender Components………………………………………………………………………………………………………………………………………………………………………………1547
Front Fender Removal and Installation………………………………………………………………………………………………………………………………………………………………….1547
Front Door Assembly Components………………………………………………………………………………………………………………………………………………………………………..1548
Front Door Assembly Removal and Installation……………………………………………………………………………………………………………………………………………………………1549
Rear Door Assembly Components…………………………………………………………………………………………………………………………………………………………………………1550
Rear Door Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………………….1550
Rear End Door Assembly Components……………………………………………………………………………………………………………………………………………………………………..1551
Rear End Door Assembly Removal and Installation…………………………………………………………………………………………………………………………………………………………1552
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1553
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1553
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1553
Recommended Service Material………………………………………………………………………………………………………………………………………………………………………….1553
Body Structure……………………………………………………………………………………………………………………………………………………………………………………………..1554
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1554
Front Bumper Components………………………………………………………………………………………………………………………………………………………………………………1554
Rear Bumper Components……………………………………………………………………………………………………………………………………………………………………………….1555
Cowl Top Components………………………………………………………………………………………………………………………………………………………………………………….1555
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1556
Body Dimensions……………………………………………………………………………………………………………………………………………………………………………………..1556
Panel Clearance……………………………………………………………………………………………………………………………………………………………………………………..1563
Paint / Coatings……………………………………………………………………………………………………………………………………………………………………………………………1564
General Description……………………………………………………………………………………………………………………………………………………………………………………..1564
Anti-Corrosion Treatment Construction………………………………………………………………………………………………………………………………………………………………….1564
Plastic Parts Finishing………………………………………………………………………………………………………………………………………………………………………………1565
Component Location………………………………………………………………………………………………………………………………………………………………………………………1565
Sealant Application Areas…………………………………………………………………………………………………………………………………………………………………………….1565
Under Coating Application Areas……………………………………………………………………………………………………………………………………………………………………….1571
Anti-Corrosion Compound Application Area……………………………………………………………………………………………………………………………………………………………….1573
Exterior Trim………………………………………………………………………………………………………………………………………………………………………………………………1574
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1574
Roof Drip Molding Removal and Installation (If Equipped)…………………………………………………………………………………………………………………………………………………1574
Roof Rail Removal and Installation (If Equipped)………………………………………………………………………………………………………………………………………………………..1575
Splash Guard Removal and Installation (If Equipped)……………………………………………………………………………………………………………………………………………………..1576
Control systems………………………………………………………………………………………………………………………………………………………………………………………………..1577
Precautions………………………………………………………………………………………………………………………………………………………………………………………………..1580
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1580
Precautions for Control Systems……………………………………………………………………………………………………………………………………………………………………….1580
Cruise Control System……………………………………………………………………………………………………………………………………………………………………………………….1581
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1581
Precautions in Diagnosing Troubles…………………………………………………………………………………………………………………………………………………………………….1581
General Description……………………………………………………………………………………………………………………………………………………………………………………..1582
Cruise Control System Construction…………………………………………………………………………………………………………………………………………………………………….1582
Components and Functions of Cruise Control System……………………………………………………………………………………………………………………………………………………….1583
Cancel Conditions of Cruise Control System……………………………………………………………………………………………………………………………………………………………..1584
Input / Output Diagram……………………………………………………………………………………………………………………………………………………………………………….1584
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1585
Cruise Control System Wiring Diagram…………………………………………………………………………………………………………………………………………………………………..1585
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1586
On-Board Diagnostic System Description…………………………………………………………………………………………………………………………………………………………………1586
Cruise Control System Diagnosis Introduction……………………………………………………………………………………………………………………………………………………………1586
Cruise Control System Check…………………………………………………………………………………………………………………………………………………………………………..1586
Customer Questionnaire (Example)………………………………………………………………………………………………………………………………………………………………………1587
DTC Check…………………………………………………………………………………………………………………………………………………………………………………………..1587
DTC Clearance……………………………………………………………………………………………………………………………………………………………………………………….1587
DTC Table…………………………………………………………………………………………………………………………………………………………………………………………..1587
Cruise Control System Symptom Diagnosis………………………………………………………………………………………………………………………………………………………………..1588
DTC P0565: Cruise Control On Signal……………………………………………………………………………………………………………………………………………………………………1589
DTC P0566 / P0567 / P0568: Cruise Control Off Signal / Resume Signal / Set Signal…………………………………………………………………………………………………………………………..1590
DTC P0571: Brake Switch Circuit……………………………………………………………………………………………………………………………………………………………………….1592
Inspection of Cruise Control System Circuit…………………………………………………………………………………………………………………………………………………………….1594
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1595
Cruise Control Switch Removal and Installation………………………………………………………………………………………………………………………………………………………….1595
Cruise Control Switch Inspection………………………………………………………………………………………………………………………………………………………………………1595
CPP Switch (for Cruise Control) Removal and Installation…………………………………………………………………………………………………………………………………………………1595
Clutch Pedal Position (CPP) Switch (for Cruise Control) Inspection and Adjustment…………………………………………………………………………………………………………………………..1596
Stop (Brake) Lamp Switch Removal and Installation……………………………………………………………………………………………………………………………………………………….1596
Stop (Brake) Lamp Switch Inspection……………………………………………………………………………………………………………………………………………………………………1596
ECM Removal and Installation………………………………………………………………………………………………………………………………………………………………………….1596
Specifications………………………………………………………………………………………………………………………………………………………………………………………….1596
Tightening Torque Specifications………………………………………………………………………………………………………………………………………………………………………1596
Body Electrical Control System……………………………………………………………………………………………………………………………………………………………………………….1597
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1597
Precautions in Diagnosing Trouble……………………………………………………………………………………………………………………………………………………………………..1597
General Description……………………………………………………………………………………………………………………………………………………………………………………..1597
BCM General Description………………………………………………………………………………………………………………………………………………………………………………1597
CAN Communication for BCM…………………………………………………………………………………………………………………………………………………………………………….1597
Theft Deterrent Light………………………………………………………………………………………………………………………………………………………………………………..1598
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1598
Body Electrical Control System Wiring Circuit Diagram……………………………………………………………………………………………………………………………………………………1598
Connector Layout Diagram of BCM……………………………………………………………………………………………………………………………………………………………………….1600
Component Location………………………………………………………………………………………………………………………………………………………………………………………1601
BCM and Related System Component Location………………………………………………………………………………………………………………………………………………………………1601
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1602
BCM Self-Diagnosis Function…………………………………………………………………………………………………………………………………………………………………………..1602
Body Electrical Control System Check…………………………………………………………………………………………………………………………………………………………………..1604
Scan Tool Data………………………………………………………………………………………………………………………………………………………………………………………1606
DTC Table…………………………………………………………………………………………………………………………………………………………………………………………..1608
DTC Check…………………………………………………………………………………………………………………………………………………………………………………………..1609
DTC Clearance……………………………………………………………………………………………………………………………………………………………………………………….1610
BCM Power Circuit and Ground Circuit Check……………………………………………………………………………………………………………………………………………………………..1611
DTC B1133 (DTC No. 1133): Battery Voltage Too High………………………………………………………………………………………………………………………………………………………1612
DTC B1141 / DTC B1142 / DTC B1143 (No. 1141 / No. 1142/ No. 1143) Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction……………………………………………………………………………..1613
DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction…………………………………………………………………………………………………………………………………………..1614
DTC B1157 (No. 1157) Air Bag Deployment Signal Input…………………………………………………………………………………………………………………………………………………….1616
DTC B1170 (No. 1170): EEPROM access error………………………………………………………………………………………………………………………………………………………………1616
DTC U1073 (No. 1073): Control Module Communication Bus Off……………………………………………………………………………………………………………………………………………….1617
DTC U1100 (No. 1100): Lost Communication with ECM……………………………………………………………………………………………………………………………………………………….1620
DTC U1101 (No. 1101): Lost communication with TCM……………………………………………………………………………………………………………………………………………………….1623
DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module…………………………………………………………………………………………………………………………………1626
Inspection of BCM and its Circuits…………………………………………………………………………………………………………………………………………………………………….1628
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1634
BCM Removal and Installation………………………………………………………………………………………………………………………………………………………………………….1634
Outside Air Temperature Sensor Removal and Installation………………………………………………………………………………………………………………………………………………….1634
Outside Air Temperature Sensor Inspection………………………………………………………………………………………………………………………………………………………………1634
DRL Function Setting Procedure………………………………………………………………………………………………………………………………………………………………………..1634
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1635
Special Tool………………………………………………………………………………………………………………………………………………………………………………………..1635
Immobilizer Control System…………………………………………………………………………………………………………………………………………………………………………………..1636
Precautions…………………………………………………………………………………………………………………………………………………………………………………………….1636
Precautions in Diagnosing Troubles…………………………………………………………………………………………………………………………………………………………………….1636
Precaution in Replacing ECM…………………………………………………………………………………………………………………………………………………………………………..1636
Precautions in Handling Immobilizer Control System………………………………………………………………………………………………………………………………………………………1636
General Description……………………………………………………………………………………………………………………………………………………………………………………..1637
Immobilizer Control System Introduction………………………………………………………………………………………………………………………………………………………………..1637
Immobilizer Control System Components Location………………………………………………………………………………………………………………………………………………………….1637
On-Board Diagnostic System Description (Self-diagnosis Function)………………………………………………………………………………………………………………………………………….1638
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1639
Immobilizer Control System Wiring Circuit Diagram……………………………………………………………………………………………………………………………………………………….1639
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1640
Immobilizer Control System Check………………………………………………………………………………………………………………………………………………………………………1640
Diagnostic Trouble Code (DTC) Check……………………………………………………………………………………………………………………………………………………………………1641
Diagnostic Trouble Code (DTC) Clearance………………………………………………………………………………………………………………………………………………………………..1641
Diagnostic Trouble Code (DTC) Table……………………………………………………………………………………………………………………………………………………………………1641
Scan Tool Data………………………………………………………………………………………………………………………………………………………………………………………1642
Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop…………………………………………………………………………………………………………………………1643
Immobilizer Indicator Lamp Remains ON after Engine Start…………………………………………………………………………………………………………………………………………………1644
DTC P1614: Transponder Response Error………………………………………………………………………………………………………………………………………………………………….1644
DTC P1615: Steering Lock Unit Communication Error (for Vehicle with Keyless Start System)……………………………………………………………………………………………………………………1645
DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System)…………………………………………………………………………………………………………………1648
DTC P1618: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System)……………………………………………………………………………………………………….1649
DTC P1621: Immobilizer Communication Line Error…………………………………………………………………………………………………………………………………………………………1651
DTC P1622: EEPROM Error………………………………………………………………………………………………………………………………………………………………………………1653
DTC P1623: Unregistered Transponder……………………………………………………………………………………………………………………………………………………………………1654
DTC P1625: Immobilizer Antenna Error…………………………………………………………………………………………………………………………………………………………………..1655
DTC P1636: Immobilizer Information Registration Failure………………………………………………………………………………………………………………………………………………….1656
DTC P1638: Immobilizer Information Mismatched…………………………………………………………………………………………………………………………………………………………..1657
Inspection of Immobilizer Control Module (ICM) and Its Circuit……………………………………………………………………………………………………………………………………………1658
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1660
Immobilizer Control Module (ICM) Removal and Installation………………………………………………………………………………………………………………………………………………..1660
Registration of the Ignition Key………………………………………………………………………………………………………………………………………………………………………1660
Procedure after ECM Replacement……………………………………………………………………………………………………………………………………………………………………….1660
Special Tools and Equipment………………………………………………………………………………………………………………………………………………………………………………1661
Special Tool………………………………………………………………………………………………………………………………………………………………………………………..1661
Keyless Start System………………………………………………………………………………………………………………………………………………………………………………………..1662
General Description……………………………………………………………………………………………………………………………………………………………………………………..1662
Keyless Start System Description………………………………………………………………………………………………………………………………………………………………………1662
Parts and Functions………………………………………………………………………………………………………………………………………………………………………………….1663
Keyless Engine Start Function…………………………………………………………………………………………………………………………………………………………………………1664
Door Lock Function of Keyless Start System……………………………………………………………………………………………………………………………………………………………..1665
Operation Area of Remote Controller……………………………………………………………………………………………………………………………………………………………………1666
Alarm Function………………………………………………………………………………………………………………………………………………………………………………………1667
CAN Communication of Keyless Start System………………………………………………………………………………………………………………………………………………………………1667
Schematic and Routing Diagram…………………………………………………………………………………………………………………………………………………………………………….1668
Keyless Start System Electric Wiring Circuit Diagram…………………………………………………………………………………………………………………………………………………….1668
Diagnostic Information and Procedures……………………………………………………………………………………………………………………………………………………………………..1669
Precautions in Diagnosing Troubles…………………………………………………………………………………………………………………………………………………………………….1669
Self-Diagnosis Function………………………………………………………………………………………………………………………………………………………………………………1669
Keyless Start System Diagnosis Introduction…………………………………………………………………………………………………………………………………………………………….1669
Keyless Start System Check……………………………………………………………………………………………………………………………………………………………………………1669
Customer Questionnaire (Example)………………………………………………………………………………………………………………………………………………………………………1670
Key Indicator Lamp Check……………………………………………………………………………………………………………………………………………………………………………..1671
DTC Check…………………………………………………………………………………………………………………………………………………………………………………………..1671
DTC Table…………………………………………………………………………………………………………………………………………………………………………………………..1672
DTC Clearance……………………………………………………………………………………………………………………………………………………………………………………….1673
Keyless Start System Symptom Diagnosis…………………………………………………………………………………………………………………………………………………………………1673
Keyless Start System Operation Inspection………………………………………………………………………………………………………………………………………………………………1674
Door Lock Operation (Keyless Start System)……………………………………………………………………………………………………………………………………………………………..1675
Inspection of Keyless Start Control Module and Its Circuits………………………………………………………………………………………………………………………………………………1675
No DTC Detection After Performing DTC Check…………………………………………………………………………………………………………………………………………………………….1681
Key Indicator Lamp Circuit Check (Key Indicator Lamp Doesn’t Light when Ignition Knob Switch is Pushed.)………………………………………………………………………………………………………1683
Keyless Start Control Module Power and Ground Circuit Check………………………………………………………………………………………………………………………………………………1684
DTC No. 11: Communication Error with Steering Lock Unit………………………………………………………………………………………………………………………………………………….1686
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction……………………………………………………………………………………………………………1687
DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM Reading Error) / (EEPROM Writing Error)…………………………………………………………………………………………….1687
DTC No. 31: Lost Communication with BCM………………………………………………………………………………………………………………………………………………………………..1688
DTC No. 33: Control Module Communication Bus Off………………………………………………………………………………………………………………………………………………………..1690
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure…………………………………………………………………………………………………………….1692
Repair Instructions……………………………………………………………………………………………………………………………………………………………………………………..1694
Antennas and Request Switches Removal and Installation…………………………………………………………………………………………………………………………………………………..1694
Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection……………………………………………………………………………………………………………………………..1695
Steering Lock Unit Removal and Installation…………………………………………………………………………………………………………………………………………………………….1695
Steering Lock Unit Inspection…………………………………………………………………………………………………………………………………………………………………………1695
Front Door Lock Switch Inspection……………………………………………………………………………………………………………………………………………………………………..1695
Keyless Start Control Module Removal and Installation……………………………………………………………………………………………………………………………………………………1696
Remote Controller Inspection………………………………………………………………………………………………………………………………………………………………………….1696
Replacement of Remote Controller Battery……………………………………………………………………………………………………………………………………………………………….1696
Registration Procedure for Remote Controller ID Code…………………………………………………………………………………………………………………………………………………….1697
COPYRIGHT……………………………………………………………………………………………………………………………………………………………………………………………………..1699
BOOKCOVER_VOL1…………………………………………………………………………………………………………………………………………………………………………………………………1700
BOOKCOVER_VOL2…………………………………………………………………………………………………………………………………………………………………………………………………1701

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