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SUZUKI RG413 RG415 IGNIS SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI RG413 RG415 IGNIS SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI RG413 RG415 IGNIS SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 633
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI RG413 RG415 IGNIS SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcover........................................................................................................... 1 99501_80G10_01E..................................................................................................... 2 Top............................................................................................................. 0 Manual List..................................................................................................... 0 Important....................................................................................................... 2 WARNING/CAUTION/NOTE........................................................................................ 2 FOREWORD........................................................................................................ 3 TABLE OF CONTENTS............................................................................................... 5 Section 0A...................................................................................................... 7 Warning, Caution and Information Labels..................................................................... 8 Vehicle Lifting Points...................................................................................... 9 Abbreviations and Symbols May Be Used in This Manual........................................................ 11 Section 0B...................................................................................................... 15 Maintenance Schedule........................................................................................ 16 Maintenance Schedule Under Normal Driving Conditions.................................................... 16 Maintenance Recommended Under Severe Driving Conditions................................................. 18 Maintenance Service......................................................................................... 19 Engine.................................................................................................. 19 Drive belt.......................................................................................... 19 Valve lash (clearance).............................................................................. 20 Engine oil and oil filter........................................................................... 20 Engine coolant...................................................................................... 22 Fuel System............................................................................................. 23 Air cleaner filter.................................................................................. 23 Emission Control System................................................................................. 24 PCV valve........................................................................................... 24 Fuel evaporative emission control system............................................................ 24 Brake................................................................................................... 24 Brake discs and pads................................................................................ 24 Brake drums and shoes............................................................................... 25 Brake lever and cable............................................................................... 25 Chassis and Body........................................................................................ 26 Tires / wheels...................................................................................... 26 Steering system..................................................................................... 27 Manual transmission oil............................................................................. 28 Recommended Fluids and Lubricants........................................................................... 28 Section 1B...................................................................................................... 29 General Description......................................................................................... 31 Major Components and Location........................................................................... 31 Diagnosis................................................................................................... 32 General Diagnosis Table................................................................................. 32 Electrical Diagnosis........................................................................................ 35 Wiring Diagram.......................................................................................... 35 A/C System Inspection of ECM and Its Circuits........................................................... 37 Refrigerant Recovery, Evacuating and Charging............................................................... 42 Operation Procedure for Refrigerant Charging............................................................ 42 On-Vehicle Service.......................................................................................... 43 Service Precaution...................................................................................... 43 Refrigerant line.................................................................................... 43 Condenser Assembly (Sport Model)........................................................................ 44 Receiver/Dryer (Sport Model)............................................................................ 45 Condenser Cooling Fan Assembly (Sport Model)............................................................ 46 Condenser Cooling Fan Motor (Sport Model)............................................................... 46 A/C Refrigerant Pressure Switch (Sport Model)........................................................... 48 A/C Compressor Relay and A/C Condenser Cooling Fan Relay (Sport Model).................................. 49 Compressor (Sport Model)................................................................................ 49 Tightening Torque Specifications............................................................................ 50 Section 3A...................................................................................................... 51 General Description......................................................................................... 52 Toe Setting............................................................................................. 52 Camber.................................................................................................. 53 Caster (Reference)...................................................................................... 53 Diagnosis................................................................................................... 53 Steering Angle Check and Adjustment..................................................................... 53 Side Slip (Reference)................................................................................... 54 Section 3B...................................................................................................... 55 On-vehicle Service.......................................................................................... 56 Lubrication............................................................................................. 56 Manual Rack and Pinion Assembly (Steering Gear Case).................................................... 57 Rack Boot/Tie Rod....................................................................................... 60 Steering Rack Plunger................................................................................... 61 Steering Pinion......................................................................................... 62 Steering Rack........................................................................................... 63 Pinion Bearing.......................................................................................... 64 Tightening Torque Specifications............................................................................ 64 Required Service Material................................................................................... 65 Special Tool................................................................................................ 65 Section 3B1..................................................................................................... 67 Wiring Diagram.............................................................................................. 69 Section 3D...................................................................................................... 71 General Description......................................................................................... 72 Front Suspension Component Locator...................................................................... 72 On-vehicle Service.......................................................................................... 73 Strut Assembly.......................................................................................... 73 Wheel Hub and Steering Knuckle.......................................................................... 75 Crossmember (Sport Model)............................................................................... 79 Tightening Torque Specifications............................................................................ 80 Required Service Material................................................................................... 80 Special Tool................................................................................................ 81 Section 3E...................................................................................................... 83 General Description......................................................................................... 84 Rear Suspension Component Construction.................................................................. 84 On-vehicle Service.......................................................................................... 87 Lateral Rod............................................................................................. 87 Rear Shock Absorber..................................................................................... 87 Coil Spring............................................................................................. 88 Trailing Arm............................................................................................ 89 Rear Axle (2WD Except Sport Model)...................................................................... 91 Rear Axle (Sport Model)................................................................................. 94 Rear Wheel Hub and Wheel Stud (Sport Model)............................................................. 98 Rear Axle Shaft and Wheel Bearing (4WD Vehicle).........................................................100 Rear Axle Housing (4WD Vehicle).........................................................................102 Tightening Torque Specifications............................................................................107 Required Service Material...................................................................................107 Special Tool................................................................................................108 Section 3F......................................................................................................109 General Description.........................................................................................110 Tires...................................................................................................110 Wheels..................................................................................................110 Replacement Wheels......................................................................................110 How to measure wheel runout.........................................................................110 Maintenance and Minor Adjustments...........................................................................111 Tire Maintenance........................................................................................111 Tire rotation (except sport model)..................................................................111 Tire rotation (sport model).........................................................................111 Section 4A......................................................................................................113 General Description.........................................................................................114 Diagnosis...................................................................................................114 Diagnosis Table.........................................................................................114 On-Vehicle Service..........................................................................................115 Front Drive Shaft Assembly Construction.................................................................115 Front Drive Shaft Assembly Removal and Installation.....................................................116 Front Drive Shaft Assembly Inspection...................................................................117 Front Drive Shaft Components............................................................................118 Front Drive Shaft Disassembly and Assembly..............................................................119 For Center Shaft and Center Bearing Support Disassembly and Assembly (2WD Model)........................126 Tightening Torque Specification.............................................................................128 Required Service Material...................................................................................128 Special Tool................................................................................................128 Section 5.......................................................................................................129 General Description.........................................................................................131 Diagnosis...................................................................................................133 Stop Light Switch Adjustment............................................................................133 Parking Brake Inspection and Adjustment.................................................................133 On-Vehicle Service..........................................................................................135 Rear Brake (Sport Model)................................................................................135 Rear brake pad......................................................................................136 Rear brake caliper assembly.........................................................................138 Rear brake disc.....................................................................................145 Master Cylinder (Sport Model)...........................................................................147 Master cylinder reservoir (sport model).............................................................148 Master cylinder assembly (sport model)..............................................................149 Brake Booster...........................................................................................153 Brake Hose/Pipe.........................................................................................154 Rear brake hose/pipe................................................................................154 Parking Brake...........................................................................................156 Parking brake cable (sport model)...................................................................156 Parking brake cable (except sport model)............................................................157 Parking brake lever.................................................................................160 Required Service Material...................................................................................161 Special Tool................................................................................................161 Section 5E......................................................................................................163 General Description.........................................................................................165 ABS Hydraulic Unit/Control Module Assembly..............................................................165 Self-diagnosis function.............................................................................165 Fail-safe function..................................................................................165 System Circuit..........................................................................................166 Diagnosis...................................................................................................167 ABS Warning Lamp Check..................................................................................167 EBD Warning Lamp (Brake Warning Lamp) Check.............................................................168 Table – A ABS Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON................168 Diagnostic Trouble Code (DTC) Check (Using SUZUKI Scan Tool)............................................170 On-Vehicle Service..........................................................................................170 ABS Hydraulic Unit Operation Check (Using SUZUKI Scan Tool).............................................170 Rear Wheel Speed Sensor Ring (Sport Model)..............................................................171 Tightening Torque Specifications............................................................................172 Special Tool................................................................................................173 Section 6-1.....................................................................................................175 General Information.........................................................................................177 Statement on Cleanliness and Care.......................................................................177 Precaution..............................................................................................178 Precaution on engine service........................................................................178 Precaution on fuel system service...................................................................178 Fuel pressure relief procedure......................................................................179 Fuel leakage check procedure........................................................................180 Diagnosis...................................................................................................180 Engine Diagnosis General Description....................................................................180 On-board Diagnostic System Description (Vehicle with Immobilizer Indicator Lamp)........................181 Warm-up cycle.......................................................................................181 Driving cycle.......................................................................................181 2 driving cycles detection logic....................................................................181 Pending DTC.........................................................................................181 Freeze frame data...................................................................................182 Priority of freeze frame data:......................................................................182 Freeze frame data clearance:........................................................................183 Data link connector (DLC)...........................................................................183 On-board Diagnostic System Description (Vehicle without Immobilizer Indicator Lamp).....................184 Data link connector (DLC)...........................................................................185 Precaution in Diagnosing Trouble for Engine.............................................................186 Engine and Emission Control System Check................................................................187 Customer Problem Inspection Form (Example)..............................................................189 Malfunction Indicator Lamp (MIL) Check..................................................................190 Diagnostic Trouble Code (DTC) Check.....................................................................190 [Using SUZUKI scan tool]............................................................................190 [Without using SUZUKI scan tool] (vehicle without immobilizer indicator lamp).......................191 Diagnostic Trouble Code (DTC) Clearance.................................................................192 Using scan tool.....................................................................................192 Without using scan tool.............................................................................192 Diagnostic Trouble Code (DTC) Table.....................................................................193 Fail-Safe Table.........................................................................................196 Visual Inspection.......................................................................................198 Engine Basic Inspection.................................................................................199 Engine Symptom Diagnosis................................................................................202 Scan Tool Data..........................................................................................210 Inspection of ECM and Its Circuits......................................................................215 Voltage check.......................................................................................215 Resistance check....................................................................................231 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” with Ignition Switch.......233 Table A-2 Malfunction Indicator Lamp Circuit Check-lamp Remains “ON” after Engine Starts................235 Table A-3 MIL Check – MIL Flashes at Ignition Switch ON (Vehicle without Immobilizer Indicator Lamp)....237 Table A-4 MIL Check – MIL Does Not Flash or Just Remains On Even with Grounding Diagnosis Switch .......238 Table A-5 ECM Power and Ground Circuit Check-MIL Doesn’t Light with Ignition Switch ON and Engine.......240 DTC P0010 Camshaft Position Actuator Circuit............................................................243 DTC P0011 Camshaft Position – Timing Over-Advanced or System Performance................................245 DTC P0012 Camshaft Position – Timing Over-Retarded......................................................245 DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction..............................247 DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction........................................250 DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction..............................253 DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction.............................................255 DTC P0121 Throttle Position Circuit Range/Performance Problem...........................................258 DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)........................261 DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)..................................263 DTC P0134 Heated Oxygen Sensor (HO2S) Circuit No Activity Detected (Sensor-1)...........................264 DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1).................265 DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)....................................267 DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2).............................270 DTC P0171 Fuel System Too Lean..........................................................................272 DTC P0172 Fuel System Too Rich..........................................................................272 DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders).............................276 DTC P0301 Cylinder 1 Misfire Detected...................................................................276 DTC P0302 Cylinder 2 Misfire Detected...................................................................276 DTC P0303 Cylinder 3 Misfire Detected...................................................................276 DTC P0304 Cylinder 4 Misfire Detected...................................................................276 DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction..................................................281 DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction..............................283 DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction................................287 DTC P0400 Exhaust Gas Recirculation Flow Malfunction....................................................290 DTC P0420 Catalyst System Efficiency Below Threshold....................................................293 DTC P0443 Purge Control Valve Circuit Malfunction.......................................................296 DTC P0480 Radiator Cooling Fan Control System Malfunction...............................................298 DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction............................................300 DTC P0505 (DTC No.26) Idle Control System Malfunction...................................................303 DTC P1450 Barometric Pressure Sensor Low/High Input.....................................................305 DTC P1451 Barometric Pressure Sensor Performance Problem................................................305 DTC P1500 Engine Starter Signal Circuit Malfunction.....................................................307 DTC P1510 ECM Back-up Power Supply Malfunction..........................................................308 Table B-1 Fuel Injector Circuit Check...................................................................309 Table B-2 Fuel Pump and Its Circuit Check...............................................................311 Table B-3 Fuel Pressure Check...........................................................................313 Table B-4 Idle Air Control System Check.................................................................315 Table B-5 A/C Signal Circuits Check (Vehicle with A/C)..................................................317 Table B-6 Electric Load Signal Circuit Check............................................................319 Table B-7 Radiator Fan Control System Check.............................................................321 Special Tool................................................................................................323 Section 6A1.....................................................................................................325 On-Vehicle Service..........................................................................................326 Timing Chain and Chain Tensioner........................................................................326 Tightening Torque Specification.............................................................................331 Section 6A2.....................................................................................................333 General Description.........................................................................................335 Engine Construction Description.........................................................................335 Engine Lubrication Description..........................................................................336 Variable Valve Timing (VVT) System Description..........................................................337 System description..................................................................................337 Oil control valve...................................................................................338 Cam timing sprocket.................................................................................338 Timing advancing....................................................................................338 Timing holding......................................................................................338 Timing retarding....................................................................................338 Targeted timing varying operation...................................................................339 Diagnosis...................................................................................................340 Diagnosis Table.........................................................................................340 Compression Check.......................................................................................340 Engine Vacuum Check.....................................................................................342 Oil Pressure Check......................................................................................344 Valve Lash (Clearance) Inspection.......................................................................346 Shim Replacement........................................................................................346 On-Vehicle Service..........................................................................................349 Air Cleaner Element Removal and Installation............................................................349 Air Cleaner Element Inspection and Cleaning.............................................................350 Knock Sensor Removal and Installation...................................................................350 Cylinder Head Cover Removal and Installation............................................................350 Throttle Body and Intake Manifold Components............................................................353 Throttle Body Removal and Installation..................................................................354 Intake Manifold Removal and Installation................................................................355 Exhaust Manifold Components.............................................................................356 Exhaust Manifold Removal and Installation...............................................................357 Oil Pan and Oil Pump Strainer Components................................................................360 Oil Pan and Oil Pump Strainer Removal and Installation..................................................360 Engine Mountings Components.............................................................................364 Unit Repair Overhaul........................................................................................365 Engine Assembly Removal and Installation................................................................365 Timing Chain Cover Components...........................................................................370 Timing Chain Cover Removal and Installation.............................................................371 Timing Chain Cover Inspection...........................................................................374 Oil seal............................................................................................374 Timing chain cover..................................................................................374 Oil control valve...................................................................................375 Oil gallery pipe....................................................................................375 Oil Pump Components.....................................................................................376 Oil Pump Removal and Installation.......................................................................376 Oil Pump Disassembly and Assembly.......................................................................377 Oil Pump Inspection.....................................................................................378 Oil seal............................................................................................378 Oil pump assembly...................................................................................379 Radial clearance....................................................................................379 Side clearance......................................................................................379 Relief valve spring free length and load............................................................380 Timing Chain and Chain Tensioner Components.............................................................380 Timing Chain and Chain Tensioner Removal and Installation...............................................381 Timing Chain and Timing Chain Tensioner Inspection......................................................384 Timing chain tensioner..............................................................................384 Crankshaft timing sprocket..........................................................................384 Timing chain........................................................................................385 Timing chain tensioner adjuster.....................................................................385 Timing chain No.1 guide.............................................................................385 Camshaft, Tappet and Shim Components....................................................................386 Camshaft, Tappet and Shim Removal and Installation......................................................386 Camshaft, Tappet and Shim Inspection....................................................................389 Intake cam timing sprocket assembly.................................................................389 Cam wear............................................................................................390 Camshaft runout.....................................................................................390 Camshaft journal wear...............................................................................390 Wear of tappet and shim.............................................................................391 Valves and Cylinder Head Components.....................................................................393 Valves and Cylinder Head Removal and Installation.......................................................394 Valves and Cylinder Head Disassembly and Assembly.......................................................396 Valves and Cylinder Head Inspection.....................................................................399 Valve guides........................................................................................399 Valves..............................................................................................400 Cylinder head.......................................................................................402 Valve springs.......................................................................................403 Cylinder head bolt (M10)............................................................................403 Pistons, Piston Rings, Connecting Rods and Cylinders Components.........................................404 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation...........................405 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly...........................406 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection.........................................408 Cylinder............................................................................................408 Pistons.............................................................................................409 Piston pin..........................................................................................410 Piston rings........................................................................................411 Connecting rod......................................................................................412 Crank pin and connecting rod bearings...............................................................413 Main Bearings, Crankshaft and Cylinder Block Components.................................................417 Main Bearings, Crankshaft and Cylinder Block Removal and Installation...................................418 Main Bearings, Crankshaft and Cylinder Block Inspection.................................................422 Main bearing cap No.1 bolt..........................................................................422 Crankshaft..........................................................................................422 Main bearings.......................................................................................423 Rear oil seal.......................................................................................428 Flywheel............................................................................................428 Sensor plate........................................................................................429 Cylinder block......................................................................................429 Required Service Material...................................................................................430 Tightening Torque Specification.............................................................................430 Special Tool................................................................................................431 Section 6B......................................................................................................433 General Description.........................................................................................434 Cooling System Circulation..............................................................................434 Coolant.................................................................................................435 Maintenance.................................................................................................436 Cooling System Flush and Refill (for M13 Engine Model)..................................................436 Cooling System Flush and Refill (for M15 Engine Model)..................................................437 On-Vehicle Service..........................................................................................439 System Components.......................................................................................439 Tightening Torque Specification.............................................................................441 Section 6E2.....................................................................................................443 General Description.........................................................................................445 Engine and Emission Control System Construction.........................................................445 Air Intake System Description...........................................................................448 Fuel Delivery System Description........................................................................449 Electronic Control System Description...................................................................450 On-Vehicle Service..........................................................................................456 Accelerator cable adjustment............................................................................456 Idle speed/idle air control (IAC) duty inspection.......................................................456 Air Intake System.......................................................................................458 Throttle body components............................................................................458 Throttle body removal and installation..............................................................458 Throttle body cleaning..............................................................................460 Idle air control valve (IAC valve) operation check..................................................460 Idle air control valve (IAC valve) removal and installation.........................................461 Idle air control valve (IAC valve) inspection.......................................................461 Oil control valve removal and installation..........................................................462 Oil control valve inspection........................................................................462 Fuel Delivery System....................................................................................463 Fuel pressure inspection............................................................................463 Fuel pump with pressure regulator on-vehicle inspection.............................................464 Fuel pump with pressure regulator removal and installation..........................................465 Fuel pump with pressure regulator inspection........................................................465 Fuel injector on-vehicle inspection.................................................................465 Fuel injector removal and installation..............................................................466 Fuel injector inspection............................................................................468 Electronic Control System...............................................................................470 Engine control module (ECM) removal and installation................................................470 Manifold absolute pressure sensor (MAP sensor) inspection...........................................471 Throttle position sensor (TP sensor) on-vehicle inspection..........................................472 Throttle position sensor (TP sensor) removal and installation.......................................472 Intake air temperature sensor (IAT sensor) removal and installation.................................473 Intake air temperature sensor (IAT sensor) inspection...............................................474 Engine coolant temperature sensor (ECT sensor) removal and installation.............................474 Engine coolant temperature sensor (ECT sensor) inspection...........................................475 Heated oxygen sensor (HO2S-1 and HO2S-2) heater on-vehicle inspection...............................475 Heated oxygen sensor (HO2S-1 and HO2S-2) removal and installation...................................476 Camshaft position sensor (CMP sensor) inspection....................................................477 Camshaft position sensor (CMP sensor) removal and installation......................................477 Crankshaft position sensor (CKP sensor) inspection..................................................477 Crankshaft position sensor (CKP sensor) removal and installation....................................478 Vehicle speed sensor (VSS) inspection...............................................................478 Vehicle speed sensor (VSS) removal and installation.................................................478 Knock sensor removal and installation...............................................................479 Main relay, fuel pump relay and radiator fan relay No.1, No.2, No.3 inspection......................479 Fuel cut operation inspection.......................................................................480 Radiator fan control system inspection..............................................................480 Emission Control System.................................................................................481 EGR system inspection...............................................................................481 EGR valve removal and installation..................................................................481 EGR valve inspection................................................................................482 Evaporative emission control system inspection......................................................482 PCV system inspection...............................................................................486 Special Tool................................................................................................488 Tightening Torque Specification.............................................................................489 Section 6F1.....................................................................................................491 General Description.........................................................................................492 System Components.......................................................................................492 On-Vehicle Service..........................................................................................493 High-Tension Cords......................................................................................493 Spark Plugs.............................................................................................494 Ignition Coil Assembly (Including Ignitor)..............................................................495 Ignition Timing.........................................................................................496 Tightening Torque Specification.............................................................................498 Special Tool................................................................................................498 Section 6K......................................................................................................499 On-Vehicle Service..........................................................................................500 Exhaust System Component................................................................................500 Section 7A......................................................................................................503 Unit Repair Overhaul........................................................................................504 Transmission Unit.......................................................................................504 Trasmission Case........................................................................................505 Gear Shifter and Differential...........................................................................506 Unit Disassembly........................................................................................508 Fifth gears.........................................................................................508 Sub Assembly Service....................................................................................509 Gear Shifter........................................................................................509 Unit Assembly...........................................................................................510 Fifth gears.........................................................................................510 Tightening Torque Specification.............................................................................513 Required Service Material...................................................................................514 Section 7A1.....................................................................................................515 General Description.........................................................................................516 Manual Transaxle Construction and Servicing.............................................................516 Transaxle Construction Diagram..........................................................................517 Diagnosis...................................................................................................518 Manual Transaxle Symptom Diagnosis......................................................................518 On-Vehicle Service..........................................................................................519 Manual Transaxle Oil Change.............................................................................519 Differential Side Oil Seal Replacement..................................................................519 Gear Shift Control Lever and Cable Components...........................................................521 Gear Shift Control Lever and Cable Removal and Installation.............................................522 Gear Shift Control Lever and Cable Adjustment...........................................................523 Vehicle Speed Sensor (VSS) Removal and Installation.....................................................524 Back Up Lamp Switch Removal and Installation............................................................525 Back Up Lamp Switch Inspection..........................................................................525 Unit Repair Overhaul........................................................................................526 Transaxle Unit Components...............................................................................526 Transaxle Unit Dismounting and Remounting...............................................................527 Transaxle Case Components...............................................................................529 Gear Shift and Select Shaft Assembly Components.........................................................531 Gear Shift and Select Shaft Assembly Removal and Installation...........................................531 Gear Shift and Select Shaft Disassembly and Assembly....................................................533 Fifth Gear Disassembly and Assembly.....................................................................533 Gear Shift Shaft, Input Shaft and Counter Shaft Removal and Installation................................538 Transaxle Right Case Disassembly and Assembly...........................................................544 Transaxle Left Case Disassembly and Assembly............................................................545 Input & Counter Shaft Components........................................................................547 Input Shaft Disassembly and Assembly....................................................................548 Counter Shaft Disassembly and Assembly..................................................................551 Gear Shift Shaft Components.............................................................................555 High Speed and Low Speed Gear Shift Shafts Inspection...................................................555 5th & Reverse Gear Shift Shafts Disassembly and Assembly................................................556 Differential Components.................................................................................556 Differential Disassembly and Assembly...................................................................557 Differential Adjustment.................................................................................558 Tightening Torque Specification.............................................................................560 Required Service Material...................................................................................561 Special Tool................................................................................................562 Section 7D......................................................................................................565 Section 8.......................................................................................................567 Diagnosis...................................................................................................569 Turn Signal and Hazard Warning Lights...................................................................569 Low Engine Coolant Temperature Light and High Engine Coolant Temperature Warning Light (Sport Model)....569 Power Door Lock System without Keyless Entry System (If Equipped).......................................570 Power Door Lock System with Keyless Entry System (If Equipped)..........................................571 Door Mirror Heater (If Equipped)........................................................................571 On-Vehicle Service..........................................................................................572 Turn Signal and Hazard Warning Lights System............................................................572 Turn signal and hazard warning lights system circuit inspection.....................................572 Combination Meter.......................................................................................573 Circuit.............................................................................................573 Stop Lamp (Brake) Switch................................................................................575 Power Door Lock System without Keyless Entry System (If Equipped).......................................577 Component location of power door lock system without keyless entry system...........................577 Power door lock system operation inspection.........................................................577 Power door lock system circuit inspection...........................................................578 Power Door Lock System with Keyless Entry System (If Equipped)..........................................579 Component location of power door lock system with keyless entry system..............................579 System description..................................................................................579 Change of signal mode...............................................................................580 Keyless entry system operation inspection...........................................................580 Keyless entry system circuit inspection.............................................................581 Transmitter.........................................................................................582 Transmitter code registration procedure.............................................................582 Seat Heater Wire....................................................................................583 Door Mirror Heater (If Equipped)........................................................................584 Mirror heater switch................................................................................584 Mirror heater.......................................................................................584 Information Display Unit................................................................................584 Section 8G......................................................................................................585 General Description.........................................................................................586 Wiring Circuit..........................................................................................587 On-Board Diagnostic System (Self-Diagnosis Function)....................................................589 Diagnosis...................................................................................................591 Precautions in Diagnosing Troubles......................................................................591 Precautions in identifying diagnostic trouble code..................................................591 Diagnostic Flow Table...................................................................................592 Diagnostic Trouble Code (DTC) Check (ECM)...............................................................594 Diagnostic Trouble Code Table...........................................................................596 Special Tool................................................................................................597 Section 9.......................................................................................................599 Body Structure..............................................................................................601 Rearend Door Spoiler Removal and Installation (Sport Model).............................................601 Sill Panel Extension (Sport Model)......................................................................602 Front Fender Extension (Sport Model)....................................................................603 Rear Fender Extension (Sport Model).....................................................................604 Front Fender............................................................................................605 Sport model.........................................................................................605 Front Bumper and Rear Bumper............................................................................606 Front and rear bumper (except sport model)..........................................................606 Front bumper (sport model)..........................................................................607 Rear bumper (sport model)...........................................................................609 Body Dimensions.........................................................................................611 Engine room.........................................................................................611 Side body...........................................................................................612 Under body..........................................................................................615 Panel Clearance.........................................................................................617 Seats.......................................................................................................619 Front Seat..............................................................................................619 Sport model.........................................................................................619 Paint and Coatings..........................................................................................621 Sealant Application Areas...............................................................................621 Under Coating Application Areas.........................................................................628 Anti-corrosion Compound Application Area................................................................630 Required Service Material...................................................................................631 Copyright.......................................................................................................633 Bookcover....................................................................................................... 0
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