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Description
Suzuki RG413 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Suzuki RG413 Service Manual – PDF DOWNLOAD
Language : English
Pages : 1146
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki RG413 Service Manual – PDF DOWNLOAD
- This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
- 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 (lubricant, sealants, etc.) 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 RG413 Service Manual – PDF DOWNLOAD
Bookcover........................................................................................................... 1 99500_80G00_01E_1................................................................................................... 2 TOP............................................................................................................. 0 MANUAL LIST..................................................................................................... 0 IMPORTANT....................................................................................................... 2 WARNING/CAUTION/NOTE........................................................................................ 2 FOREWORD........................................................................................................ 3 TABLE OF CONTENTS............................................................................................... 4 SECTION 0A...................................................................................................... 5 HOW TO USE THIS MANUAL...................................................................................... 6 PRECAUTIONS................................................................................................. 7 PRECAUTION FOR VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT (AIR BAG) SYSTEM......................... 7 DIAGNOSIS........................................................................................... 7 SERVICING AND HANDLING.............................................................................. 8 GENERAL PRECAUTIONS..................................................................................... 10 PRECAUTIONS FOR CATALYTIC CONVERTER..................................................................... 13 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT................................................ 13 PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLE........................................................... 14 PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE.............................................................. 15 ELECTRICAL CIRCUIT INSPECTION PROCEDURE................................................................. 17 OPEN CIRCUIT CHECK.................................................................................. 17 CONTINUITY CHECK.................................................................................... 18 VOLTAGE CHECK....................................................................................... 19 SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)........................................................ 20 INTERMITTENT AND POOR CONNECTION........................................................................ 20 IDENTIFICATION INFORMATION.................................................................................. 22 VEHICLE IDENTIFICATION NUMBER........................................................................... 22 ENGINE IDENTIFICATION NUMBER............................................................................ 22 TRANSMISSION IDENTIFICATION NUMBER...................................................................... 22 WARNING, CAUTION AND INFORMATION LABELS..................................................................... 23 VEHICLE LIFTING POINTS...................................................................................... 24 ABBREVIATIONS AND SYMBOLS MAY BE USED IN THIS MANUAL........................................................ 26 FASTENER INFORMATION........................................................................................ 29 METRIC FASTENERS........................................................................................ 29 FASTENER STRENGTH IDENTIFICATION........................................................................ 29 STANDARD TIGHTENING TORQUE.............................................................................. 29 SECTION 0B...................................................................................................... 31 MAINTENANCE SCHEDULE........................................................................................ 32 MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS.................................................... 32 MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS................................................. 34 MAINTENANCE SERVICE......................................................................................... 35 ENGINE.................................................................................................. 35 DRIVE BELT.......................................................................................... 35 VALVE LASH (CLEARANCE).............................................................................. 36 ENGINE OIL AND OIL FILTER........................................................................... 36 ENGINE COOLANT...................................................................................... 38 EXHAUST SYSTEM...................................................................................... 40 IGNITION SYSTEM......................................................................................... 40 SPARK PLUGS......................................................................................... 40 FUEL SYSTEM............................................................................................. 40 AIR CLEANER FILTER.................................................................................. 40 FUEL LINES AND CONNECTIONS.......................................................................... 41 FUEL FILTER......................................................................................... 41 FUEL TANK........................................................................................... 42 EMISSION CONTROL SYSTEM................................................................................. 42 PCV VALVE........................................................................................... 42 FUEL EVAPORATIVE EMISSION CONTROL SYSTEM............................................................ 42 BRAKE................................................................................................... 42 BRAKE DISCS AND PADS (FRONT)........................................................................ 42 BRAKE DRUMS AND SHOES (REAR)........................................................................ 43 BRAKE HOSES AND PIPES............................................................................... 43 BRAKE FLUID......................................................................................... 43 BRAKE LEVER AND CABLE............................................................................... 43 CHASSIS AND BODY........................................................................................ 44 CLUTCH.............................................................................................. 44 TIRES / WHEELS...................................................................................... 44 SUSPENSION SYSTEM................................................................................... 45 STEERING SYSTEM..................................................................................... 45 DRIVE SHAFT (AXLE) BOOTS / PROPELLER SHAFTS (4WD)................................................... 46 MANUAL TRANSMISSION OIL............................................................................. 47 AUTOMATIC TRANSMISSION FLUID........................................................................ 47 TRANSFER OIL (4WD) AND REAR DIFFERENTIAL OIL (4WD).................................................. 48 ALL LATCHES, HINGES AND LOCKS....................................................................... 49 FINAL INSPECTION............................................................................................ 49 RECOMMENDED FLUIDS AND LUBRICANTS........................................................................... 51 SECTION 1A...................................................................................................... 53 GENERAL DESCRIPTION......................................................................................... 54 DIAGNOSIS................................................................................................... 55 DIAGNOSIS TABLE......................................................................................... 55 WIRING CIRCUIT.......................................................................................... 56 ON-VEHICLE SERVICE.......................................................................................... 57 HEATER UNIT............................................................................................. 57 BLOWER FAN MOTOR........................................................................................ 59 BLOWER FAN MOTOR RESISTOR............................................................................... 60 HEATER CONTROL ASSEMBLY................................................................................. 61 AIR INLET BOX........................................................................................... 64 VENTILATION LOUVER...................................................................................... 65 REQUIRED SERVICE MATERIALS.................................................................................. 66 SECTION 1B...................................................................................................... 67 GENERAL DESCRIPTION......................................................................................... 69 REFRIGERANT CIRCULATION................................................................................. 69 REFRIGERANT TYPE........................................................................................ 69 MAJOR COMPONENTS AND LOCATION........................................................................... 70 DIAGNOSIS................................................................................................... 71 GENERAL DIAGNOSIS TABLE................................................................................. 71 ABNORMAL NOISE DIAGNOSIS................................................................................ 73 QUICKLY CHECKING OF REFRIGERANT CHARGE.................................................................. 75 PERFORMANCE DIAGNOSIS................................................................................... 76 PERFORMANCE DIAGNOSIS TABLE......................................................................... 78 DETAIL DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30°C (86°F))......................................... 79 COMPRESSOR DRIVE BELT................................................................................... 81 ELECTRICAL DIAGNOSIS........................................................................................ 82 WIRING DIAGRAM.......................................................................................... 82 A/C SYSTEM INSPECTION OF ECM AND ITS CIRCUITS........................................................... 83 REFRIGERANT RECOVERY, EVACUATING AND CHARGING............................................................... 86 OPERATION PROCEDURE FOR REFRIGERANT CHARGING............................................................ 86 RECOVERY................................................................................................ 87 REPLENISHING COMPRESSOR OIL............................................................................. 87 EVACUATING.............................................................................................. 88 EVACUATING PROCEDURE................................................................................ 88 CHECKING SYSTEM FOR PRESSURE LEAKS.................................................................. 89 CHARGING................................................................................................ 90 CHARGING PROCEDURE.................................................................................. 90 REMOVING MANIFOLD GAUGE SET............................................................................. 92 LEAK TEST............................................................................................... 92 LIQUID LEAK DETECTORS............................................................................... 92 ON-VEHICLE SERVICE.......................................................................................... 93 SERVICE PRECAUTION...................................................................................... 93 REFRIGERANT LINE.................................................................................... 93 HANDLING REFRIGERANT HFC-134a (R-134a).............................................................. 94 REFRIGERANT RECOVERY................................................................................ 94 REFRIGERANT CHARGE.................................................................................. 94 CONDENSER ASSEMBLY...................................................................................... 94 RECEIVER/DRYER.......................................................................................... 96 RADIATOR/CONDENSER COOLING FAN MOTOR.................................................................... 97 COOLING UNIT (EVAPORATOR)............................................................................... 98 A/C EVAPORATOR TEMPERATURE SENSOR....................................................................... 100 EXPANSION VALVE......................................................................................... 100 A/C REFRIGERANT PRESSURE SWITCH......................................................................... 101 A/C SWITCH.............................................................................................. 102 RADIATOR/CONDENSER COOLING FAN MOTOR RELAY No.1, No.2 and No.3.......................................... 102 COMPRESSOR.............................................................................................. 102 MAGNET CLUTCH........................................................................................... 104 LIP TYPE SEAL........................................................................................... 107 REQUIRED SERVICE MATERIAL................................................................................... 109 SPECIAL TOOL................................................................................................ 110 SECTION 3....................................................................................................... 111 DIAGNOSIS................................................................................................... 112 GENERAL DIAGNOSIS....................................................................................... 112 DIAGNOSIS TABLE......................................................................................... 112 TIRE DIAGNOSIS.......................................................................................... 115 IRREGULAR AND/OR PREMATURE WEAR..................................................................... 115 WEAR INDICATORS..................................................................................... 115 RADIAL TIRE WADDLE.................................................................................. 116 RADIAL TIRE LEAD.................................................................................... 117 VIBRATION DIAGNOSIS..................................................................................... 117 SECTION 3A...................................................................................................... 119 GENERAL DESCRIPTION......................................................................................... 120 TOE SETTING............................................................................................. 120 CAMBER.................................................................................................. 120 ALIGNMENT SERVICE DATA (REFERENCE)...................................................................... 120 DIAGNOSIS................................................................................................... 121 DIAGNOSIS TABLE......................................................................................... 121 PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT................................................... 121 TOE ADJUSTMENT.......................................................................................... 121 CAMBER AND CASTER CHECK AND ADJUSTMENT.................................................................. 122 STEERING ANGLE CHECK AND ADJUSTMENT..................................................................... 122 SIDE SLIP (REFERENCE)................................................................................... 122 SECTION 3B...................................................................................................... 123 GENERAL DESCRIPTION......................................................................................... 124 DIAGNOSIS................................................................................................... 125 ON-VEHICLE SERVICE.......................................................................................... 126 LUBRICATION............................................................................................. 126 TIE ROD END............................................................................................. 128 MANUAL RACK AND PINION ASSEMBLY (STEERING GEAR CASE).................................................... 129 RACK BOOT/TIE ROD....................................................................................... 132 STEERING RACK PLUNGER................................................................................... 134 STEERING PINION......................................................................................... 136 STEERING RACK........................................................................................... 137 PINION BEARING.......................................................................................... 139 RACK BUSHING............................................................................................ 140 REQUIRED SERVICE MATERIAL................................................................................... 141 SPECIAL TOOL................................................................................................ 142 SECTION 3B1..................................................................................................... 143 GENERAL DESCRIPTION......................................................................................... 144 SYSTEM COMPONENTS....................................................................................... 144 WIRING DIAGRAM.......................................................................................... 145 DIAGNOSIS................................................................................................... 146 ON-BOARD DIAGNOSTIC SYSTEM.............................................................................. 146 PRECAUTIONS IN DIAGNOSING TROUBLES...................................................................... 146 SYSTEM CHECK FLOW TABLE................................................................................. 147 MALFUNCTION INDICATOR LAMP (“EPS” WARNING LAMP) CHECK................................................... 149 DTC CHECK............................................................................................... 150 DTC CLEARANCE........................................................................................... 151 SERIAL DATA LINK CIRCUIT CHECK.......................................................................... 152 DTC TABLE............................................................................................... 153 TABLE A - MALFUNCTION INDICATOR LAMP DOES NOT COME ON AT IGNITION SWITCH ON BUT LEAVING ENGINE OFF...... 155 TABLE B - MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON...................................... 157 TABLE C - MALFUNCTION INDICATOR LAMP DOES NOT FLASH, JUST REMAINS ON OR JUST REMAINS OFF EVEN WIT....... 157 DTC C1111 (DTC No.11) TORQUE SENSOR MAIN CIRCUIT FAILURE................................................ 158 DTC C1113 (DTC No.13) TORQUE SENSOR MAIN AND SUB CIRCUIT FAILURE........................................ 158 DTC C1115 (DTC No.15) TORQUE SENSOR SUB CIRCUIT FAILURE................................................. 158 DTC C1114 (DTC No.14) TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAILURE..................................... 159 DTC C1116 (DTC No.16) TORQUE SENSOR 8V POWER SUPPLY CIRCUIT FAILURE..................................... 160 DTC C1121/C1123/C1124 (DTC No.21/23/24) VSS CIRCUIT FAILURE............................................. 161 DTC C1122 (DTC No.22) ENGINE SPEED SIGNAL CIRCUIT FAILURE............................................... 162 DTC C1141/C1142/C1143/C1144/C1145 (DTC No.41/42/43/44/45) MOTOR CIRCUIT FAILURE......................... 163 DTC C1151 (DTC No.51) CLUTCH CIRCUIT FAILURE............................................................ 164 DTC C1153(DTC No.53) P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAILURE.................................... 166 DTC C1152/C1154/C1155 (DTC No.52/54/55) P/S CONTROL MODULE FAILURE...................................... 166 TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON BOARD DIAGNOSTIC SYSTEM)............................. 167 INSPECTION OF P/S CONTROL MODULE AND ITS CIRCUITS....................................................... 168 STEERING WHEEL PLAY INSPECTION.......................................................................... 170 STEERING FORCE INSPECTION............................................................................... 170 ON-VEHICLE SERVICE.......................................................................................... 171 P/S CONTROL MODULE...................................................................................... 171 TORQUE SENSOR........................................................................................... 171 MOTOR AND CLUTCH........................................................................................ 172 STEERING COLUMN ASSEMBLY................................................................................ 173 SPECIAL TOOL................................................................................................ 173 SECTION 3C...................................................................................................... 175 GENERAL DESCRIPTION......................................................................................... 176 STEERING COLUMN......................................................................................... 176 STEERING WHEEL AND DRIVER AIR BAG (INFLATOR) MODULE..................................................... 176 DIAGNOSIS................................................................................................... 176 INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT........................................................... 176 ON-VEHICLE SERVICE.......................................................................................... 177 SERVICE PRECAUTIONS..................................................................................... 177 SERVICE AND DIAGNOSIS............................................................................... 177 DISABLING AIR BAG SYSTEM............................................................................ 177 ENABLING AIR BAG SYSTEM............................................................................. 177 HANDLING AND STORAGE................................................................................ 178 DISPOSAL............................................................................................ 178 DRIVER AIR BAG (INFLATOR) MODULE........................................................................ 178 STEERING WHEEL.......................................................................................... 180 CENTERING CONTACT COIL.................................................................................. 181 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY............................................................ 182 STEERING COLUMN ASSEMBLY................................................................................ 184 STEERING LOCK ASSEMBLY (IGNITION SWITCH)................................................................ 190 STEERING LOWER SHAFT.................................................................................... 191 CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE....................................... 192 SPECIAL TOOL................................................................................................ 193 SECTION 3D...................................................................................................... 195 GENERAL DESCRIPTION......................................................................................... 195 DIAGNOSIS................................................................................................... 197 STABILIZER BAR AND/OR BUSHING CHECK..................................................................... 197 STRUT ASSEMBLY CHECK.................................................................................... 197 SUSPENSION CONTROL ARM / STEERING KNUCKLE CHECK......................................................... 198 SUSPENSION CONTROL ARM BUSHING CHECK.................................................................... 198 SUSPENSION CONTROL ARM JOINT CHECK...................................................................... 198 FRONT SUSPENSION FASTENERS CHECK........................................................................ 199 WHEEL DISC, NUT AND BEARING CHECK....................................................................... 199 ON-VEHICLE SERVICE.......................................................................................... 200 STRUT ASSEMBLY.......................................................................................... 200 STABILIZER BAR AND/OR BUSHINGS.......................................................................... 203 WHEEL HUB AND STEERING KNUCKLE.......................................................................... 205 SUSPENSION CONTROL ARM / BUSHING........................................................................ 210 REQUIRED SERVICE MATERIAL................................................................................... 213 SPECIAL TOOL................................................................................................ 213 SECTION 3E...................................................................................................... 215 GENERAL DESCRIPTION......................................................................................... 216 DIAGNOSIS................................................................................................... 218 REAR SHOCK ABSORBER CHECK............................................................................... 218 TRAILING ARM, LATERAL ROD, REAR AXLE, PEAR AXLE HOUSING AND COIL SPRING CHECK........................... 218 BUMP STOPPER/SPRING UPPER SEAT CHECK.................................................................... 219 REAR SUSPENSION FASTENERS............................................................................... 219 WHEEL DISC, NUT AND BEARING CHECK....................................................................... 219 ON-VEHICLE SERVICE.......................................................................................... 220 LATERAL ROD............................................................................................. 220 REAR SHOCK ABSORBER..................................................................................... 221 COIL SPRING............................................................................................. 221 BUMP STOPPER............................................................................................ 224 SPRING UPPER SEAT....................................................................................... 225 TRAILING ARM............................................................................................ 225 REAR AXLE (2WD VEHICLE)................................................................................. 228 WHEEL BEARING AND WHEEL STUD (2WD VEHICLE).............................................................. 233 REAR AXLE SHAFT AND WHEEL BEARING (4WD VEHICLE)......................................................... 235 REAR AXLE SHAFT OIL SEAL (4WD VEHICLE).................................................................. 239 REAR AXLE HOUSING (4WD VEHICLE)......................................................................... 240 REQUIRED SERVICE MATERIAL................................................................................... 246 SPECIAL TOOL................................................................................................ 246 SECTION 3F...................................................................................................... 247 GENERAL DESCRIPTION......................................................................................... 248 TIRES................................................................................................... 248 WHEELS.................................................................................................. 248 REPLACEMENT TIRES....................................................................................... 248 REPLACEMENT WHEELS...................................................................................... 248 HOW TO MEASURE WHEEL RUNOUT......................................................................... 249 METRIC LUG NUTS AND WHEEL STUDS..................................................................... 249 DIAGNOSIS................................................................................................... 249 DIAGNOSIS TABLE......................................................................................... 249 BALANCING WHEELS........................................................................................ 249 GENERAL BALANCE PROCEDURES.............................................................................. 250 OFF-VEHICLE BALANCING............................................................................... 250 ON-VEHICLE BALANCING................................................................................ 250 MAINTENANCE AND MINOR ADJUSTMENTS........................................................................... 251 WHEEL MAINTENANCE....................................................................................... 251 WHEEL ATTACHING STUDS............................................................................... 251 MATCHED TIRES AND WHEELS............................................................................ 251 TIRE MAINTENANCE........................................................................................ 251 TIRE PLACARD........................................................................................ 251 INFLATION OF TIRES.................................................................................. 252 TIRE ROTATION....................................................................................... 252 ON-VEHICLE SERVICE.......................................................................................... 253 WHEEL................................................................................................... 253 TIRE.................................................................................................... 254 MOUNTING AND DISMOUNTING............................................................................ 254 REPAIR.............................................................................................. 254 SECTION 4A...................................................................................................... 255 GENERAL DESCRIPTION......................................................................................... 256 COMPONENT............................................................................................... 256 DIAGNOSIS................................................................................................... 256 DIAGNOSIS TABLE......................................................................................... 256 DRIVE SHAFT BOOT CHECK.................................................................................. 256 ON-VEHICLE SERVICE.......................................................................................... 257 DRIVE SHAFT ASSEMBLY.................................................................................... 258 TIGHTENING TORQUE SPECIFICATION............................................................................. 270 REQUIRED SERVICE MATERIAL................................................................................... 270 SPECIAL TOOL................................................................................................ 270 SECTION 4B...................................................................................................... 271 GENERAL DESCRIPTION......................................................................................... 271 DIAGNOSIS................................................................................................... 271 DIAGNOSIS TABLE......................................................................................... 271 PROPELLER SHAFT JOINT CHECK............................................................................. 272 ON-VEHICLE SERVICE.......................................................................................... 272 TIGHTENING TORQUE SPECIFICATION............................................................................. 274 SECTION 5....................................................................................................... 275 GENERAL DESCRIPTION......................................................................................... 276 DIAGNOSIS................................................................................................... 278 ROAD TESTING BRAKES..................................................................................... 278 BRAKE FLUID LEAKS....................................................................................... 278 SUBSTANDARD OR CONTAMINATED BRAKE FLUID................................................................. 278 DIAGNOSIS TABLE......................................................................................... 279 BRAKE PEDAL FREE HEIGHT ADJUSTMENT...................................................................... 282 BRAKE PEDAL PLAY INSPECTION............................................................................. 282 STOP LIGHT SWITCH ADJUSTMENT............................................................................ 282 EXCESSIVE PEDAL TRAVEL INSPECTION....................................................................... 283 FRONT BRAKE PAD INSPECTION.............................................................................. 283 BRAKE DISC INSPECTION................................................................................... 283 PARKING BRAKE INSPECTION AND ADJUSTMENT................................................................. 284 BOOSTER OPERATION INSPECTION............................................................................ 285 FLUID PRESSURE TEST (IF EQUIPPED WITH LSPV)............................................................. 286 MASTER CYLINDER AND BRAKE FLUID LEVEL INSPECTION........................................................ 288 BRAKE HOSE AND PIPE INSPECTION.......................................................................... 289 HOSE................................................................................................ 289 PIPE................................................................................................ 289 ON-VEHICLE SERVICE.......................................................................................... 289 AIR BLEEDING OF BRAKE SYSTEM............................................................................ 289 FRONT BRAKE............................................................................................. 291 BRAKE PAD........................................................................................... 291 CALIPER ASSEMBLY.................................................................................... 293 BRAKE DISC.......................................................................................... 297 REAR BRAKE.............................................................................................. 299 BRAKE DRUM.......................................................................................... 300 BRAKE SHOE.......................................................................................... 303 WHEEL CYLINDER...................................................................................... 304 BRAKE BACK PLATE (FOR 2WD VEHICLE).................................................................. 305 BRAKE BACK PLATE (FOR 4WD VEHICLE).................................................................. 307 MASTER CYLINDER......................................................................................... 307 MASTER CYLINDER RESERVOIR........................................................................... 307 MASTER CYLINDER ASSEMBLY............................................................................ 308 BRAKE BOOSTER........................................................................................... 312 BRAKE HOSE/PIPE......................................................................................... 315 FRONT BRAKE HOSE/PIPE............................................................................... 315 REAR BRAKE HOSE/PIPE................................................................................ 318 PARKING BRAKE CABLE..................................................................................... 320 LSPV (LOAD SENSING PROPORTIONING VALVE) ASSEMBLY (IF EQUIPPED).......................................... 322 REQUIRED SERVICE MATERIAL................................................................................... 324 SPECIAL TOOL................................................................................................ 324 SECTION 5E...................................................................................................... 327 GENERAL DESCRIPTION......................................................................................... 328 COMPONENTS/PARTS LOCATION AND BRAKE HOSE/PIPE ROUTING................................................... 328 SYSTEM SCHEMATIC........................................................................................ 330 ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY.............................................................. 331 SELF-DIAGNOSIS FUNCTION............................................................................. 331 FAIL-SAFE FUNCTION.................................................................................. 331 SYSTEM CIRCUIT.......................................................................................... 332 DIAGNOSIS................................................................................................... 334 PRECAUTION IN DIAGNOSING TROUBLES....................................................................... 334 ABS DIAGNOSTIC FLOW TABLE............................................................................... 335 ABS WARNING LAMP CHECK.................................................................................. 338 EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK............................................................. 338 TABLE – A ABS WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME “ON” AT IGNITION SWITCH ON................ 339 TABLE – B ABS WARNING LAMP CIRCUIT CHECK – LAMP COMES “ON” STEADY....................................... 340 TABLE – C ABS WARNING LAMP CIRCUIT CHECK – THE LAMP FLASHES CONTINUOUSLY WHILE IGNITION SWITCH IS ON.... 341 TABLE – D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAGNOSIS SWITCH TERMINAL CONNECTED TO GROUND........... 342 TABLE – E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK – LAMP COMES “ON” STEADY.......................... 343 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (USING ABS WARNING LAMP)............................................ 344 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (USING SUZUKI SCAN TOOL)............................................ 345 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE................................................................. 345 DIAGNOSTIC TROUBLE CODE (DTC) TABLE..................................................................... 346 DTC C1013 (DTC 13) – SYSTEM SPECIFICATIONS DIFFERENT FROM ABS CONTROL MODULE SPECIFICATIONS............. 348 DTC C1015 (DTC 15) – G SENSOR CIRCUIT................................................................... 348 DTC C1021 (DTC 21), DTC C1022 (DTC 22) – RIGHT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING.......... 350 DTC C1025 (DTC 25), DTC C1026 (DTC 26) – LEFT-FRONT WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING........... 350 DTC C1031 (DTC 31), DTC C1032 (DTC 32) – RIGHT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING........... 350 DTC C1035 (DTC 35), DTC C1036 (DTC 36) – LEFT-REAR WHEEL SPEED SENSOR CIRCUIT OR SENSOR RING............ 350 DTC C1041 (DTC 41) – RIGHT-FRONT INLET SOLENOID CIRCUIT................................................. 352 DTC C1045 (DTC 45) – LEFT-FRONT INLET SOLENOID CIRCUIT.................................................. 352 DTC C1051 (DTC 51) – RIGHT-REAR INLET SOLENOID CIRCUIT.................................................. 352 DTC C1055 (DTC 55) – LEFT-REAR INLET SOLENOID CIRCUIT................................................... 352 DTC C1042 (DTC 42) – RIGHT-FRONT OUTLET SOLENOID CIRCUIT................................................ 352 DTC C1046 (DTC 46) – LEFT-FRONT OUTLET SOLENOID CIRCUIT................................................. 352 DTC C1052 (DTC 52) – RIGHT-REAR OUTLET SOLENOID CIRCUIT................................................. 352 DTC C1056 (DTC 56) – LEFT-REAR OUTLET SOLENOID CIRCUIT.................................................. 352 DTC C1057 (DTC 57) – POWER SOURCE CIRCUIT............................................................... 353 DTC C1061 (DTC 61) – ABS PUMP MOTOR CIRCUIT............................................................. 354 DTC C1063 (DTC 63) – ABS FAIL-SAFE RELAY CIRCUIT........................................................ 355 DTC C1071 (DTC 71) – ABS CONTROL MODULE................................................................. 356 ON-VEHICLE SERVICE.......................................................................................... 357 PRECAUTIONS............................................................................................. 357 ABS HYDRAULIC UNIT OPERATION CHECK (USING SUZUKI SCAN TOOL)............................................. 357 ABS HYDRAULIC UNIT OPERATION CHECK (NOT USING SUZUKI SCAN TOOL)......................................... 357 ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY.............................................................. 359 FRONT WHEEL SPEED SENSOR................................................................................ 361 FRONT WHEEL SPEED SENSOR RING........................................................................... 363 REAR WHEEL SPEED SENSOR................................................................................. 364 REAR WHEEL SPEED SENSOR RING (FOR 2WD VEHICLE).......................................................... 367 REAR WHEEL SPEED SENSOR RING (FOR 4WD VEHICLE).......................................................... 368 G SENSOR (FOR 4WD VEHICLE ONLY)......................................................................... 369 SPECIAL TOOL................................................................................................ 370 SECTION 6....................................................................................................... 371 GENERAL INFORMATION......................................................................................... 374 STATEMENT ON CLEANLINESS AND CARE....................................................................... 374 GENERAL INFORMATION ON ENGINE SERVICE................................................................... 374 PRECAUTION ON FUEL SYSTEM SERVICE................................................................... 375 FUEL PRESSURE RELIEF PROCEDURE...................................................................... 376 FUEL LEAKAGE CHECK PROCEDURE........................................................................ 376 ENGINE DIAGNOSIS............................................................................................ 376 GENERAL DESCRIPTION..................................................................................... 376 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITH IMMOBILIZER INDICATOR LAMP).................................... 377 ON-BOARD DIAGNOSTIC SYSTEM (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)................................. 380 PRECAUTION IN DIAGNOSING TROUBLE........................................................................ 381 ENGINE DIAGNOSTIC FLOW TABLE............................................................................ 382 CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE).......................................................... 384 MALFUNCTION INDICATOR LAMP (MIL) CHECK.............................................................. 385 DIAGNOSTIC TROUBLE CODE (DTC) CHECK................................................................. 385 DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE............................................................. 386 DIAGNOSTIC TROUBLE CODE (DTC) TABLE................................................................. 387 FAIL-SAFE TABLE..................................................................................... 390 VISUAL INSPECTION................................................................................... 392 ENGINE BASIC INSPECTION............................................................................. 393 ENGINE DIAGNOSIS TABLE.............................................................................. 396 SCAN TOOL DATA.......................................................................................... 401 INSPECTION OF ECM AND ITS CIRCUITS...................................................................... 406 ECM VOLTAGE VALUES TABLE............................................................................ 407 TERMINAL RESISTANCE TABLE........................................................................... 413 COMPONENT LOCATION...................................................................................... 415 TABLE A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK - LAMP DOES NOT COME “ON” AT IGNITION SWITCH O....... 416 TABLE A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK - LAMP REMAINS “ON” AFTER ENGINE STARTS.............. 417 TABLE A-3 MIL CHECK - MIL FLASHES AT IGNITION SWITCH ON (VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP).... 418 TABLE A-4 MIL CHECK - MIL DOES NOT FLASH OR JUST REMAINS ON EVEN WITH GROUNDING DIAGNOSIS SWITCH ....... 418 TABLE A-5 ECM POWER AND GROUND CIRCUIT CHECK - MIL DOESN’T LIGHT AT IGNITION SWITCH ON AND ENGINE....... 419 DTC P0105 (DTC NO.11) MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT MALFUNCTION.............................. 422 DTC P0110 (DTC NO.18) INTAKE AIR TEMP. (IAT) CIRCUIT MALFUNCTION........................................ 425 DTC P0115 (DTC NO.19) ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT MALFUNCTION.............................. 427 DTC P0120 (DTC NO.13) THROTTLE POSITION CIRCUIT MALFUNCTION............................................. 430 DTC P0121 THROTTLE POSITION CIRCUIT RANGE/PERFORMANCE PROBLEM........................................... 433 DTC P0130 (DTC NO.14) HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-1)........................ 436 DTC P0133 HEATED OXYGEN SENSOR (HO2S) CIRCUIT SLOW RESPONSE (SENSOR-1).................................. 438 DTC P0134 HEATED OXYGEN SENSOR (HO2S) CIRCUIT NO ACTIVITY DETECTED (SENSOR-1)........................... 439 DTC P0135 (DTC NO.14) HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-1)................. 440 DTC P0136 HEATED OXYGEN SENSOR (HO2S) CIRCUIT MALFUNCTION (SENSOR-2).................................... 442 DTC P0141 HEATED OXYGEN SENSOR (HO2S) HEATER CIRCUIT MALFUNCTION (SENSOR-2)............................. 444 DTC P0171 FUEL SYSTEM TOO LEAN.......................................................................... 446 DTC P0172 FUEL SYSTEM TOO RICH.......................................................................... 446 DTC P0300 RANDOM MISFIRE DETECTED (MISFIRE DETECTED AT 2 OR MORE CYLINDERS)............................. 451 DTC P0301 CYLINDER 1 MISFIRE DETECTED................................................................... 451 DTC P0302 CYLINDER 2 MISFIRE DETECTED................................................................... 451 DTC P0303 CYLINDER 3 MISFIRE DETECTED................................................................... 451 DTC P0304 CYLINDER 4 MISFIRE DETECTED................................................................... 451 DTC P0325 (DTC NO.17) KNOCK SENSOR CIRCUIT MALFUNCTION.................................................. 456 DTC P0335 (DTC NO.23) CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT MALFUNCTION.............................. 458 DTC P0340 (DTC NO.15) CAMSHAFT POSITION (CMP) SENSOR CIRCUIT MALFUNCTION................................ 461 DTC P0400 EXHAUST GAS RECIRCULATION FLOW MALFUNCTION.................................................... 464 DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD.................................................... 467 DTC P0443 PURGE CONTROL VALVE CIRCUIT MALFUNCTION....................................................... 470 DTC P0480 RADIATOR COOLING FAN CONTROL SYSTEM MALFUNCTION............................................... 471 DTC P0500 (DTC NO.16) VEHICLE SPEED SENSOR (VSS) MALFUNCTION............................................ 473 DTC P0505 (DTC NO.26) IDLE CONTROL SYSTEM MALFUNCTION................................................... 475 DTC P1450 BAROMETRIC PRESSURE SENSOR LOW/HIGH INPUT..................................................... 478 DTC P1451 BAROMETRIC PRESSURE SENSOR PERFORMANCE PROBLEM................................................ 478 DTC P1500 ENGINE STARTER SIGNAL CIRCUIT MALFUNCTION..................................................... 480 DTC P1510 ECM BACK-UP POWER SUPPLY MALFUNCTION.......................................................... 481 DTC P1600 SERIAL COMMUNICATION PROBLEM BETWEEN ECM AND TCM.............................................. 482 DTC P1717 A/T DRIVE RANGE (PARK/NEUTRAL POSITION) SIGNAL CIRCUIT MALFUNCTION............................ 484 TABLE B-1 FUEL INJECTOR CIRCUIT CHECK................................................................... 487 TABLE B-2 FUEL PUMP AND ITS CIRCUIT CHECK............................................................... 488 TABLE B-3 FUEL PRESSURE CHECK........................................................................... 490 TABLE B-4 IDLE AIR CONTROL SYSTEM CHECK................................................................. 492 TABLE B-5 A/C SIGNAL CIRCUITS CHECK (VEHICLE WITH A/C).................................................. 494 TABLE B-6 ELECTRIC LOAD SIGNAL CIRCUIT CHECK............................................................ 496 TABLE B-7 RADIATOR FAN CONTROL SYSTEM CHECK............................................................. 498 SPECIAL TOOL................................................................................................ 500 SECTION 6A1..................................................................................................... 503 GENERAL DESCRIPTION......................................................................................... 504 ENGINE.................................................................................................. 504 ENGINE LUBRICATION...................................................................................... 505 DIAGNOSIS................................................................................................... 506 DIAGNOSIS TABLE......................................................................................... 506 COMPRESSION CHECK....................................................................................... 506 ENGINE VACUUM CHECK..................................................................................... 508 OIL PRESSURE CHECK...................................................................................... 509 VALVE LASH (CLEARANCE).................................................................................. 511 ON-VEHICLE SERVICE.......................................................................................... 514 AIR CLEANER ELEMENT..................................................................................... 514 AIR CLEANER ASSEMBLY AND RESONATOR...................................................................... 515 KNOCK SENSOR............................................................................................ 515 CYLINDER HEAD COVER..................................................................................... 515 THROTTLE BODY AND INTAKE MANIFOLD....................................................................... 518 EXHAUST MANIFOLD........................................................................................ 521 OIL PAN AND OIL PUMP STRAINER........................................................................... 523 TIMING CHAIN COVER...................................................................................... 527 OIL PUMP................................................................................................ 532 TIMING CHAIN AND CHAIN TENSIONER........................................................................ 536 CAMSHAFT, TAPPET AND SHIM............................................................................... 541 VALVES AND CYLINDER HEAD................................................................................ 546 PISTONS, PISTON RINGS, CONNECTING RODS AND CYLINDERS.................................................... 559 ENGINE MOUNTINGS........................................................................................ 569 UNIT REPAIR OVERHAUL........................................................................................ 570 ENGINE ASSEMBLY......................................................................................... 570 MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK............................................................ 575 REQUIRED SERVICE MATERIAL................................................................................... 587 TIGHTENING TORQUE SPECIFICATION............................................................................. 588 SPECIAL TOOL................................................................................................ 589 SECTION 6B...................................................................................................... 591 GENERAL DESCRIPTION......................................................................................... 592 COOLING SYSTEM CIRCULATION.............................................................................. 592 COOLANT................................................................................................. 593 DIAGNOSIS................................................................................................... 594 DIAGNOSIS TABLE......................................................................................... 594 SYSTEM CIRCUIT.......................................................................................... 595 SYSTEM CIRCUIT INSPECTION............................................................................... 595 MAINTENANCE................................................................................................. 596 COOLANT LEVEL CHECK..................................................................................... 596 ENGINE COOLING SYSTEM INSPECTION AND SERVICE............................................................ 597 COOLING SYSTEM FLUSH AND REFILL......................................................................... 597 WATER PUMP/GENERATOR DRIVE BELT TENSION INSPECTION AND ADJUSTMENT....................................... 599 ON-VEHICLE SERVICE.......................................................................................... 600 SYSTEM COMPONENTS....................................................................................... 600 COOLING SYSTEM DRAINING................................................................................. 601 COOLING SYSTEM REFILL................................................................................... 601 COOLING WATER PIPES OR HOSES............................................................................ 602 THERMOSTAT.............................................................................................. 602 RADIATOR................................................................................................ 604 RADIATOR AND CONDENSER COOLING FAN...................................................................... 605 RADIATOR AND CONDENSER COOLING FAN RELAY................................................................ 605 WATER PUMP/GENERATOR DRIVE BELT......................................................................... 605 WATER PUMP.............................................................................................. 606 ECT SENSOR.............................................................................................. 608 REQUIRED SERVICE MATERIAL................................................................................... 608 TIGHTENING TORQUE SPECIFICATION............................................................................. 608 SECTION 6C...................................................................................................... 609 GENERAL DESCRIPTION......................................................................................... 609 ON-VEHICLE SERVICE.......................................................................................... 610 COMPONENTS.............................................................................................. 610 PRECAUTIONS............................................................................................. 611 FUEL LINES.............................................................................................. 612 FUEL PIPE............................................................................................... 612 FUEL FILLER CAP......................................................................................... 613 FUEL TANK INLET VALVE................................................................................... 614 FUEL TANK............................................................................................... 615 FUEL PUMP ASSEMBLY...................................................................................... 618 DISASSEMBLY AND REASSEMBLY.......................................................................... 620 SPECIAL TOOL................................................................................................ 622 TIGHTENING TORQUE SPECIFICATION............................................................................. 622 SECTION 6E1..................................................................................................... 623 GENERAL DESCRIPTION......................................................................................... 624 AIR INTAKE SYSTEM....................................................................................... 627 FUEL DELIVERY SYSTEM.................................................................................... 628 FUEL PUMP........................................................................................... 628 ELECTRONIC CONTROL SYSTEM............................................................................... 629 ENGINE & EMISSION CONTROL INPUT/OUTPUT TABLE........................................................ 630 ECM INPUT/OUTPUT CIRCUIT DIAGRAM.................................................................... 631 ECM TERMINAL ARRANGEMENT TABLE...................................................................... 635 ON-VEHICLE SERVICE.......................................................................................... 637 ACCELERATOR CABLE ADJUSTMENT............................................................................ 637 IDLE SPEED/IDLE AIR CONTROL (IAC) DUTY INSPECTION....................................................... 637 IDLE MIXTURE INSPECTION / ADJUSTMENT (VEHICLE WITHOUT HEATED OXYGEN SENSOR)............................. 639 AIR INTAKE SYSTEM....................................................................................... 640 THROTTLE BODY....................................................................................... 640 IDLE AIR CONTROL VALVE (IAC VALVE).................................................................. 642 FUEL DELIVERY SYSTEM.................................................................................... 643 FUEL PRESSURE INSPECTION............................................................................ 643 FUEL PUMP WITH PRESSURE REGULATOR................................................................... 644 FUEL INJECTOR....................................................................................... 645 ELECTRONIC CONTROL SYSTEM............................................................................... 649 ENGINE CONTROL MODULE (ECM)......................................................................... 649 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP SENSOR)...................................................... 649 THROTTLE POSITION SENSOR (TP SENSOR)................................................................ 650 INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR).......................................................... 651 ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR)...................................................... 652 HEATED OXYGEN SENSOR (HO2S-1 AND HO2S-2)............................................................ 653 CAMSHAFT POSITION SENSOR............................................................................ 654 CRANKSHAFT POSITION SENSOR.......................................................................... 654 VEHICLE SPEED SENSOR (VSS).......................................................................... 655 FUEL LEVEL SENSOR (GAUGE)........................................................................... 655 KNOCK SENSOR (IF EQUIPPED).......................................................................... 655 MAIN RELAY, FUEL PUMP RELAY AND RADIATOR FAN RELAY NO.1............................................. 655 FUEL CUT OPERATION.................................................................................. 656 RADIATOR FAN CONTROL SYSTEM......................................................................... 656 RADIATOR FAN RELAY NO. 2 AND NO.3................................................................... 656 OUTPUT SIGNALS OF THROTTLE VALVE OPENING AND ENGINE COOLANT TEMP. (VEHICLE WITH A/T ONLY)........... 658 EMISSION CONTROL SYSTEM................................................................................. 658 EGR SYSTEM.......................................................................................... 658 EVAPORATIVE EMISSION CONTROL SYSTEM................................................................. 659 PCV SYSTEM.......................................................................................... 661 SPECIAL TOOL................................................................................................ 662 TIGHTENING TORQUE SPECIFICATION............................................................................. 663 SECTION 6F1..................................................................................................... 664 GENERAL DESCRIPTION......................................................................................... 665 SYSTEM COMPONENTS....................................................................................... 665 SYSTEM WIRING DIAGRAM................................................................................... 666 DIAGNOSIS................................................................................................... 666 ON-VEHICLE SERVICE.......................................................................................... 668 IGNITION SPARK TEST..................................................................................... 668 HIGH-TENSION CORDS...................................................................................... 668 SPARK PLUGS............................................................................................. 669 IGNITION COIL ASSEMBLY (INCLUDING IGNITOR).............................................................. 670 CRANKSHAFT POSITION SENSOR (CKP SENSOR)................................................................. 670 IGNITION TIMING......................................................................................... 671 SPECIAL TOOL................................................................................................ 672 SECTION 6G...................................................................................................... 674 GENERAL DESCRIPTION......................................................................................... 675 CRANKING CIRCUIT........................................................................................ 675 DIAGNOSIS................................................................................................... 675 DIAGNOSIS TABLE......................................................................................... 675 PERFORMANCE TEST........................................................................................ 677 PULL-IN TEST........................................................................................ 677 HOLD-IN TEST........................................................................................ 677 PLUNGER AND PINION RETURN TEST...................................................................... 677 NO-LOAD PERFORMANCE TEST............................................................................ 678 ON-VEHICLE SERVICE.......................................................................................... 678 STARTING MOTOR.......................................................................................... 678 DISMOUNTING......................................................................................... 678 REMOUNTING.......................................................................................... 678 DISASSEMBLY AND REASSEMBLY.......................................................................... 679 SPECIFICATION............................................................................................... 681 1.0 kW TYPE............................................................................................. 681 1.2 kW TYPE............................................................................................. 681 REQUIRED SERVICE MATERIAL................................................................................... 681 SECTION 6H...................................................................................................... 682 GENERAL DESCRIPTION......................................................................................... 683 BATTERY................................................................................................. 683 CARRIER AND HOLD-DOWN............................................................................... 683 ELECTROLYTE FREEZING................................................................................ 683 SULFATION........................................................................................... 683 BUILT-IN INDICATOR (IF EQUIPPED).................................................................... 683 CARE OF BATTERY..................................................................................... 684 GENERATOR............................................................................................... 685 DIAGNOSIS................................................................................................... 686 BATTERY................................................................................................. 686 VISUAL INSPECTION................................................................................... 686 HYDROMETER TEST..................................................................................... 686 GENERATOR............................................................................................... 687 CHARGING INDICATOR LAMP OPERATION................................................................... 687 UNDERCHARGED BATTERY................................................................................ 688 OVERCHARGED BATTERY................................................................................. 689 ON-VEHICLE SERVICE.......................................................................................... 690 BATTERY................................................................................................. 690 JUMP STARTING IN CASE OF EMERGENCY.................................................................. 690 DISMOUNTING......................................................................................... 691 HANDLING............................................................................................ 691 REMOUNTING.......................................................................................... 691 GENERATOR............................................................................................... 691 GENERATOR BELT...................................................................................... 691 DISMOUNTING AND REMOUNTING.......................................................................... 692 DISASSEMBLY AND REASSEMBLY.......................................................................... 692 INSPECTION.......................................................................................... 693 SPECIFICATION............................................................................................... 695 BATTERY................................................................................................. 695 GENERATOR............................................................................................... 695 TIGHTENING TORQUE SPECIFICATION............................................................................. 695 SECTION 6K...................................................................................................... 696 GENERAL DESCRIPTION......................................................................................... 697 MAINTENANCE................................................................................................. 697 ON-VEHICLE SERVICE.......................................................................................... 698 EXHAUST MANIFOLD........................................................................................ 699 EXHAUST PIPE............................................................................................ 699 SECTION 7A...................................................................................................... 0 SECTION 7B...................................................................................................... 42 SECTION 7C...................................................................................................... 182 SECTION 7D...................................................................................................... 198 SECTION 7F...................................................................................................... 222 SECTION 8....................................................................................................... 244 SECTION 8G...................................................................................................... 278 SECTION 9....................................................................................................... 304 SECTION 10...................................................................................................... 366 SECTION 10B..................................................................................................... 374 COPYRIGHT....................................................................................................... 446 BOOKCOVER....................................................................................................... 0 99500_80G00_01E_2................................................................................................... 700 TOP............................................................................................................. 0 MANUAL LIST..................................................................................................... 0 IMPORTANT....................................................................................................... 0 FOREWORD........................................................................................................ 1 TABLE OF CONTENTS............................................................................................... 2 SECTION 0A...................................................................................................... 3 SECTION 0B...................................................................................................... 29 SECTION 1A...................................................................................................... 51 SECTION 1B...................................................................................................... 65 SECTION 3....................................................................................................... 109 SECTION 3A...................................................................................................... 117 SECTION 3B...................................................................................................... 121 SECTION 3B1..................................................................................................... 141 SECTION 3C...................................................................................................... 173 SECTION 3D...................................................................................................... 193 SECTION 3E...................................................................................................... 213 SECTION 3F...................................................................................................... 245 SECTION 4A...................................................................................................... 253 SECTION 4B...................................................................................................... 269 SECTION 5....................................................................................................... 273 SECTION 5E...................................................................................................... 325 SECTION 6....................................................................................................... 369 SECTION 6A1..................................................................................................... 501 SECTION 6B...................................................................................................... 589 SECTION 6C...................................................................................................... 607 SECTION 6E1..................................................................................................... 621 SECTION 6F1..................................................................................................... 662 SECTION 6G...................................................................................................... 672 SECTION 6H...................................................................................................... 680 SECTION 6K...................................................................................................... 694 SECTION 7A...................................................................................................... 700 GENERAL DESCRIPTION......................................................................................... 701 CONSTRUCTION AND SERVICING.............................................................................. 701 TRANSMISSION FOR 2WD MODEL.......................................................................... 702 TRANSMISSION FOR 4WD MODEL.......................................................................... 703 DIAGNOSIS................................................................................................... 704 ON-VEHICLE SERVICE.......................................................................................... 704 OIL CHANGE.............................................................................................. 705 DIFFERENTIAL SIDE OIL SEAL.............................................................................. 705 GEAR SHIFT CONTROL LEVER AND CABLE...................................................................... 707 VEHICLE SPEED SENSOR (VSS).............................................................................. 709 UNIT REPAIR OVERHAUL........................................................................................ 710 TRANSMISSION UNIT....................................................................................... 710 TRASMISSION CASE........................................................................................ 711 INPUT & COUNTER SHAFT................................................................................... 712 GEAR SHIFTER & DIFFERENTIAL............................................................................. 713 TRANSMISSION UNIT....................................................................................... 715 UNIT DISASSEMBLY........................................................................................ 716 FIFTH GEARS......................................................................................... 716 GEAR SHIFTER, INPUT SHAFT AND COUNTER SHAFT......................................................... 718 RIGHT CASE.......................................................................................... 719 SUB ASSEMBLY SERVICE.................................................................................... 720 RIGHT CASE.......................................................................................... 720 LEFT CASE........................................................................................... 720 INPUT SHAFT ASSEMBLY................................................................................ 721 COUNTER SHAFT ASSEMBLY.............................................................................. 724 GEAR SHIFTER........................................................................................ 728 DIFFERENTIAL ASSEMBLY............................................................................... 730 UNIT ASSEMBLY........................................................................................... 733 DIFFERENTIAL TO LEFT CASE........................................................................... 733 FIFTH GEARS......................................................................................... 735 GEAR SHIFT AND SELECT SHAFT ASSEMBLY................................................................ 738 TIGHTENING TORQUE SPECIFICATION............................................................................. 739 REQUIRED SERVICE MATERIAL................................................................................... 740 SPECIAL TOOL................................................................................................ 740 SECTION 7B...................................................................................................... 742 GENERAL DESCRIPTION......................................................................................... 744 ELECTRONIC SHIFT CONTROL SYSTEM......................................................................... 747 TRANSMISSION CONTROL MODULE (TCM)................................................................... 748 FAIL SAFE FUNCTION.................................................................................. 749 CHANGE MECHANISM.................................................................................... 751 AUTOMATIC GEAR SHIFT DIAGRAM........................................................................ 752 DIAGNOSIS................................................................................................... 754 AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE............................................................ 754 TROUBLE DIAGNOSIS TABLE................................................................................. 759 STALL TEST.......................................................................................... 761 TIME LAG TEST....................................................................................... 762 LINE PRESSURE TEST.................................................................................. 763 ENGINE BRAKE TEST................................................................................... 764 “P” RANGE TEST...................................................................................... 764 ELECTRONIC CONTROL SYSTEM DIAGNOSIS..................................................................... 765 PRECAUTIONS IN DIAGNOSING TROUBLES.................................................................. 765 DTC CHECK........................................................................................... 766 DTC CLEARANCE....................................................................................... 768 DTC TABLE........................................................................................... 769 TCM POWER AND GROUND CIRCUIT CHECK.................................................................. 771 DTC P0715 (DTC NO.14) INPUT/TURBINE SPEED SENSOR CIRCUIT MALFUNCTION................................ 772 DTC P0730 (DTC NO. 18) INCORRECT GEAR RATIO......................................................... 774 DTC P0753 (DTC NO.21/22) SHIFT SOLENOID-A (NO.1) ELECTRICAL......................................... 776 DTC P0758 (DTC NO.23/24) SHIFT SOLENOID-B (NO.2) ELECTRICAL......................................... 776 DTC P0743 (DTC NO.25/26) TCC (LOCK-UP CLUTCH) SYSTEM ELECTRICAL..................................... 776 DTC P0741 (DTC NO.29) TCC (LOCK-UP) SOLENOID PERFORMANCE OR STUCK OFF............................... 778 DTC P0720 (DTC NO. 31) OUTPUT SHAFT SPEED SENSOR CIRCUIT MALFUNCTION................................ 779 DTC P1700 (DTC NO.32/33) THROTTLE POSITION SIGNAL INPUT MALFUNCTION................................. 782 DTC P0705 (DTC NO.34) TRANSMISSION RANGE SENSOR (SWITCH) CIRCUIT MALFUNCTION........................ 784 DTC P0725 (DTC NO.35) ENGINE SPEED INPUT CIRCUIT MALFUNCTION........................................ 786 DTC P0710 (DTC No.36/38) TRANSMISSION TEMPERATURE SENSOR CIRCUIT MALFUNCTION........................ 788 DTC P0763 (DTC NO.43) SHIFT SOLENOID-C (NO.3) ELECTRICAL............................................ 790 DTC P0768 (DTC NO.45) SHIFT SOLENOID-B (NO.4) ELECTRICAL............................................ 790 DTC P0773 (DTC NO.48) SHIFT SOLENOID-E (NO.5) ELECTRICAL............................................ 790 DTC P1709 (DTC NO.51) ENGINE COOLANT TEMPERATURE/BAROMETRIC PRESSURE SIGNAL CIRCUIT................. 792 DTC P0702/P1702 (DTC No.52)TRANSMISSION CONTROL SYSTEM ELECTRICAL OR INTERNAL MALFUNCTION OF TCM.... 793 INSPECTION OF TCM AND ITS CIRCUITS.................................................................. 794 ON-VEHICLE SERVICE.......................................................................................... 796 MAINTENANCE SERVICE..................................................................................... 796 FLUID LEVEL AT NORMAL OPERATING TEMPERATURE......................................................... 796 FLUID LEVEL AT ROOM TEMPERATURE..................................................................... 797 FLUID CHANGE........................................................................................ 797 SELECTOR LEVER.......................................................................................... 798 TRANSMISSION RANGE SENSOR (SHIFT SWITCH)................................................................ 799 SELECTOR CABLE.......................................................................................... 801 OUTPUT SHAFT SPEED SENSOR (A/T VSS)..................................................................... 803 INPUT SHAFT SPEED SENSOR................................................................................ 804 VEHICLE SPEED SENSOR (VSS).............................................................................. 804 THROTTLE POSITION SENSOR................................................................................ 804 ENGINE COOLANT TEMP. (ECT) SENSOR....................................................................... 805 DROPPING RESISTOR....................................................................................... 805 O/D OFF SWITCH.......................................................................................... 806 SHIFT SOLENOID VALVES AND TRANSMISSION TEMPERATURE SENSOR............................................... 806 SHIFT SOLENOID VALVES............................................................................... 807 TRANSMISSION TEMPERATURE SENSOR..................................................................... 807 DIFFERENTIAL SIDE OIL SEAL.............................................................................. 809 TRANSMISSION CONTROL MODULE (TCM)....................................................................... 810 LEARNING CONTROL INITIALIZATION..................................................................... 811 BRAKE INTERLOCK SYSTEM (IF EQUIPPED).................................................................... 811 KEY INTERLOCK CABLE (IF EQUIPPED)....................................................................... 813 TRANSMISSION UNIT REPAIR OVERHAUL........................................................................... 816 DISMOUNTING............................................................................................. 817 REMOUNTING.............................................................................................. 818 UNIT DISASSEMBLY........................................................................................ 819 DISASSEMBLY/ASSEMBLY OF SUBASSEMBLY..................................................................... 829 OIL PUMP............................................................................................ 829 FRONT CLUTCH (C2 CLUTCH)............................................................................ 832 REAR CLUTCH (C1 CLUTCH)............................................................................. 836 DIRECT CLUTCH (C0 CLUTCH)........................................................................... 841 PLANETARY SET....................................................................................... 845 VALVE BODY.......................................................................................... 847 DIFFERENTIAL ASSEMBLY............................................................................... 853 REAR COVER (O/D BRAKE PISTON ASSEMBLY).............................................................. 856 PLANETARY SUN GEAR NO.1 ASSEMBLY.................................................................... 856 TORQUE CONVERTER HOUSING............................................................................ 857 TRANSMISSION CASE................................................................................... 858 UNIT ASSEMBLY........................................................................................... 859 TIGHTENING TORQUE SPECIFICATION............................................................................. 877 SPECIAL TOOL................................................................................................ 878 REQUIRED SERVICE MATERIAL................................................................................... 880 SECTION 7C...................................................................................................... 882 GENERAL DESCRIPTION......................................................................................... 883 DIAGNOSIS................................................................................................... 884 ON-VEHICLE SERVICE.......................................................................................... 885 CLUTCH CABLE............................................................................................ 885 CLUTCH PEDAL AND CLUTCH PEDAL BRACKET................................................................... 887 CLUTCH PEDAL HEIGHT................................................................................. 888 CLUTCH PEDAL FREE TRAVEL............................................................................ 888 UNIT REPAIR OVERHAUL........................................................................................ 889 CLUTCH COVER, CLUTCH DISC AND FLYWHEEL.................................................................. 889 CLUTCH RELEASE SYSTEM................................................................................... 892 TIGHTENING TORQUE SPECIFICATION............................................................................. 895 REQUIRED SERVICE MATERIAL................................................................................... 895 SPECIAL TOOL................................................................................................ 895 SECTION 7D...................................................................................................... 898 GENERAL DESCRIPTION......................................................................................... 899 DIAGNOSIS................................................................................................... 899 ON-VEHICLE SERVICE.......................................................................................... 900 UNIT REPAIR OVERHAUL........................................................................................ 901 UNIT DISMOUNTING........................................................................................ 902 UNIT DISASSEMBLY........................................................................................ 903 TRANSFER ASSEMBLY................................................................................... 903 REDUCTION DRIVEN GEAR............................................................................... 904 INTERMEDIATE SHAFT.................................................................................. 905 TRANSFER OUTPUT RETAINER............................................................................ 906 COMPONENT INSPECTION.................................................................................... 907 UNIT ASSEMBLY........................................................................................... 907 REDUCTION DRIVEN GEAR............................................................................... 907 BEVEL GEAR SHIM..................................................................................... 908 TRANSFER OUTPUT RETAINER............................................................................ 909 RIGHT CASE.......................................................................................... 913 LEFT CASE........................................................................................... 914 TRANSFER ASSEMBLY................................................................................... 914 BEVEL GEAR BACK LASH................................................................................ 915 UNIT INSTALLATION....................................................................................... 917 TIGHTENING TORQUE SPECIFICATION............................................................................. 919 REQUIRED SERVICE MATERIAL................................................................................... 919 SPECIAL TOOL................................................................................................ 919 SECTION 7F...................................................................................................... 922 GENERAL DESCRIPTION......................................................................................... 923 VISCOUS COUPLING........................................................................................ 923 DIAGNOSIS................................................................................................... 924 ON-VEHICLE SERVICE.......................................................................................... 925 OIL CHANGE.............................................................................................. 925 UNIT REPAIR OVERHAUL........................................................................................ 926 DIFFERENTIAL UNIT....................................................................................... 927 UNIT DISASSEMBLY........................................................................................ 928 SUB-ASSEMBLY REPAIR..................................................................................... 929 VISCOUS COUPLING.................................................................................... 929 REAR DIFFERENTIAL................................................................................... 931 UNIT ASSEMBLY........................................................................................... 941 TIGHTENING TORQUE SPECIFICATION............................................................................. 941 REQUIRED SERVICE MATERIAL................................................................................... 942 SPECIAL TOOL................................................................................................ 942 SECTION 8....................................................................................................... 944 DIAGNOSIS................................................................................................... 946 HEADLIGHT............................................................................................... 946 HEADLIGHTS WITH LEVELING SYSTEM (IF EQUIPPED)........................................................... 946 TURN SIGNAL AND HAZARD WARNING LIGHT.................................................................... 946 CLEARANCE, TAIL AND LICENSE PLATE LIGHT................................................................. 947 BACK-UP LIGHT........................................................................................... 947 BRAKE LIGHT............................................................................................. 947 FRONT FOG LIGHT (IF EQUIPPED)........................................................................... 947 REAR FOG LIGHT (IF EQUIPPED)............................................................................ 947 SPEEDOMETER AND VSS..................................................................................... 948 FUEL METER AND FUEL LEVEL SENSOR (GAUGE UNIT)........................................................... 948 ENGINE COOLANT TEMPERATURE (ECT) METER AND ECT SENSOR................................................... 948 OIL PRESSURE WARNING LIGHT.............................................................................. 948 BRAKE AND PARKING BRAKE WARNING LIGHT................................................................... 949 REAR WINDOW DEFOGGER.................................................................................... 949 WIPERS AND WASHERS...................................................................................... 949 FRONT WIPER AND WASHER.............................................................................. 949 REAR WIPER AND WASHER (IF EQUIPPED)................................................................. 949 POWER WINDOW CONTROL SYSTEM (IF EQUIPPED)............................................................... 950 CIGARETTE LIGHTER....................................................................................... 950 POWER DOOR LOCK CONTROL SYSTEM (IF EQUIPPED)............................................................ 950 KEYLESS ENTRY SYSTEM (IF EQUIPPED)...................................................................... 950 POWER DOOR MIRROR CONTROL SYSTEM (IF EQUIPPED).......................................................... 951 INTERIOR LIGHT.......................................................................................... 951 HORN.................................................................................................... 951 IGNITION KEY REMAINDER (IF EQUIPPED) AND LIGHT REMAINDER WARNING BUZZER................................. 951 SEAT BELT WARNING LIGHT (IF EQUIPPED)................................................................... 951 FRONT SEAT HEATER (IF EQUIPPED)......................................................................... 952 ON-VEHICLE SERVICE.......................................................................................... 952 CAUTIONS IN SERVICING................................................................................... 952 HEADLIGHT............................................................................................... 952 HEADLIGHT SWITCH.................................................................................... 952 HEADLIGHT ASSEMBLY.................................................................................. 953 HEADLIGHT BULB...................................................................................... 953 HEADLIGHT AIMING ADJUSTMENT WITH SCREEN............................................................. 954 HEADLIGHT LEVELING SWITCH (IF EQUIPPED)............................................................. 955 TURN SIGNAL AND HAZARD WARNING LIGHTS................................................................... 955 TURN SIGNAL LIGHT SWITCH............................................................................ 955 REMOVAL AND INSTALLATION............................................................................ 955 TURN SIGNAL AND HAZARD RELAY........................................................................ 956 HAZARD SWITCH....................................................................................... 956 FRONT FOG LIGHTS (IF EQUIPPED).......................................................................... 956 FRONT FOG LIGHT SWITCH.............................................................................. 956 REAR FOG LIGHT (IF EQUIPPED)............................................................................ 957 REAR FOG LIGHT SWITCH............................................................................... 957 IGNITION SWITCH......................................................................................... 957 COMBINATION METER....................................................................................... 958 CIRCUIT............................................................................................. 958 FUEL METER AND FUEL LEVEL SENSOR (GAUGE UNIT)........................................................... 959 FUEL LEVEL METER.................................................................................... 959 FUEL LEVEL SENSOR (GAUGE UNIT)...................................................................... 960 SPEED METER AND VSS..................................................................................... 960 VSS................................................................................................. 960 ENGINE COOLANT TEMPERATURE (ECT) METER AND SENSOR....................................................... 960 ENGINE COOLANT TEMPERATURE (ECT) METER.............................................................. 960 ECT SENSOR.......................................................................................... 961 OIL PRESSURE WARNING LIGHT.............................................................................. 961 OIL PRESSURE SWITCH................................................................................. 961 BRAKE FLUID LEVEL AND PARKING BRAKE WARNING LIGHT....................................................... 961 BRAKE FLUID LEVEL SWITCH............................................................................ 961 PARKING BRAKE SWITCH................................................................................ 962 REAR WINDOW DEFOGGER.................................................................................... 962 DEFOGGER SWITCH..................................................................................... 962 DEFOGGER WIRE....................................................................................... 962 WIPERS AND WASHERS...................................................................................... 964 COMPONENTS.......................................................................................... 964 FRONT WIPER AND WASHER SWITCH....................................................................... 964 FRONT WIPER MOTOR................................................................................... 966 WASHER TANK AND WASHER PUMP......................................................................... 967 REAR WIPER AND WASHER SWITCH (IF EQUIPPED).......................................................... 968 REAR WIPER MOTOR.................................................................................... 968 IGNITION KEY REMAINDER (IF EQUIPPED) AND LIGHT REMAINDER WARNING BUZZER................................. 968 POWER WINDOW CONTROL SYSTEM (IF EQUIPPED)............................................................... 969 POWER WINDOW MAIN SWITCH............................................................................ 969 POWER WINDOW SUB SWITCH............................................................................. 970 DOOR SWITCH............................................................................................. 970 STOP LAMP (BRAKE) SWITCH................................................................................ 970 POWER DOOR LOCK SYSTEM (IF EQUIPPED).................................................................... 971 DOOR LOCK CONTROLLER................................................................................ 971 DRIVER’S DOOR KNOB SWITCH........................................................................... 971 DOOR LOCK ACTUATOR.................................................................................. 972 KEYLESS ENTRY SYSTEM (IF EQUIPPED)...................................................................... 972 DOOR LOCK CONTROLLER................................................................................ 972 DOOR LOCK ACTUATOR.................................................................................. 972 RECEIVER............................................................................................ 973 TRANSMITTER......................................................................................... 973 POWER DOOR MIRROR CONTROL SYSTEM (IF EQUIPPED).......................................................... 974 MIRROR SWITCH....................................................................................... 974 DOOR MIRROR ACTUATOR................................................................................ 975 FRONT SEAT HEATER (IF EQUIPPED)......................................................................... 975 SEAT HEATER SWITCH (DRIVER AND PASSENGER SIDE)...................................................... 975 SEAT HEATER WIRE.................................................................................... 976 SECTION 8G...................................................................................................... 978 GENERAL DESCRIPTION......................................................................................... 979 WIRING CIRCUIT.......................................................................................... 980 ON-BOARD DIAGNOSTIC SYSTEM (SELF-DIAGNOSIS FUNCTION).................................................... 981 DIAGNOSIS................................................................................................... 982 PRECAUTIONS IN DIAGNOSING TROUBLES...................................................................... 982 PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE.................................................. 982 DIAGNOSTIC FLOW TABLE................................................................................... 983 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (IMMOBILIZER CONTROL MODULE)........................................ 984 DIAGNOSTIC TROUBLE CODE (DTC) CHECK (ECM)............................................................... 985 DIAGNOSTIC TROUBLE CODE TABLE........................................................................... 986 TABLE A - IMMOBILIZER INDICATOR LAMP CHECK (IMMOBILIZER INDICATOR LAMP DOES NOT LIGHT AT IGNITION....... 987 TABLE B - IMMOBILIZER INDICATOR LAMP CHECK (IMMOBILIZER INDICATOR LAMP REMAINS ON AFTER ENGINE ST....... 988 TABLE C - DTC IS NOT OUTPUT FROM IMMOBILIZER CONTROL MODULE............................................. 989 DTC11/32 TRANSPONDER CODE NOT MATCHED................................................................... 990 DTC31 TRANSPONDER CODE NOT REGISTERED................................................................... 991 DTC12 FAULT IN IMMOBILIZER CONTROL MODULE............................................................... 991 DTC13 NO TRANSPONDER CODE TRANSMITTED OR COIL ANTENNA OPENED/SHORTED.................................... 992 DTC21 ECM/IMMOBILIZER CONTROL MODULE CODE NOT MATCHED (IMMOBILIZER CONTROL MODULE SIDE)................. 993 DTC P1623 ECM/IMMOBILIZER CONTROL MODULE CODE NOT MATCHED (ECM SIDE).................................... 993 DTC P1620 ECM/IMMOBILIZER CONTROL MODULE CODE NOT REGISTERED............................................ 993 DTC P1622 FAULT IN ECM.................................................................................. 993 DTC22 IGNITION SWITCH CIRCUIT OPEN/SHORT................................................................ 994 DTC23 NO ECM/IMMOBILIZER CONTROL MODULE CODE TRANSMITTED FROM ECM OR DLC CIRCUIT OPENED/SHORTED......... 995 DTC P1621 NO ECM/IMMOBILIZER CONTROL MODULE CODE TRANSMITTED FROM IMMOBILIZER CONTROL MODULE OR D....... 995 INSPECTION OF ECM, IMMOBILIZER CONTROL MODULE AND ITS CIRCUIT........................................... 997 ON-VEHICLE SERVICE.......................................................................................... 998 PRECAUTIONS IN HANDLING IMMOBILIZER CONTROL SYSTEM...................................................... 998 IMMOBILIZER CONTROL MODULE.............................................................................. 999 HOW TO REGISTER IGNITION KEY................................................................................1000 PROCEDURE AFTER IMMOBILIZER CONTROL MODULE REPLACEMENT......................................................1001 PROCEDURE AFTER ECM REPLACEMENT.............................................................................1002 SPECIAL TOOL................................................................................................1002 SECTION 9.......................................................................................................1004 GLASS, WINDOWS AND MIRRORS..................................................................................1005 FRONT DOOR GLASS........................................................................................1005 FRONT DOOR WINDOW REGULATOR.................................................................................1009 DOOR MIRROR.............................................................................................1010 REAR DOOR GLASS (IF EQUIPPED)...........................................................................1011 REAR DOOR WINDOW REGULATOR..............................................................................1014 WINDOW SHIELD...........................................................................................1015 QUARTER WINDOW..........................................................................................1020 BACK DOOR GLASS.........................................................................................1021 BODY STRUCTURE..............................................................................................1022 FRONT DOOR ASSEMBLY.....................................................................................1022 REAR DOOR ASSEMBLY......................................................................................1025 BACK DOOR ASSEMBLY......................................................................................1026 HOOD....................................................................................................1028 FRONT FENDER............................................................................................1029 FRONT BUMPER AND REAR BUMPER............................................................................1030 ROOF RAIL (IF EQUIPPED).................................................................................1031 BODY DIMENSIONS.........................................................................................1032 ENGINE ROOM.........................................................................................1032 BACK DOOR...........................................................................................1033 SIDE BODY...........................................................................................1034 UNDER BODY..........................................................................................1037 PANEL CLEARANCE.........................................................................................1039 INSTRUMENTATION AND DRIVER INFORMATION......................................................................1041 INSTRUMENT PANEL........................................................................................1041 SEATS.......................................................................................................1043 FRONT SEAT..............................................................................................1043 REAR SEAT...............................................................................................1044 SECURITY AND LOCKS..........................................................................................1045 FRONT DOOR LOCK ASSEMBLY................................................................................1045 REAR DOOR LOCK ASSEMBLY (IF EQUIPPED)...................................................................1047 BACK DOOR LOCK ASSEMBLY.................................................................................1048 KEY CODING..............................................................................................1049 KEY USAGE AND IDENTIFICATION........................................................................1049 IGNITION SWITCH LOCK CYLINDER.......................................................................1050 EXTERIOR AND INTERIOR TRIM..................................................................................1050 FLOOR CARPET............................................................................................1050 HEAD LINING.............................................................................................1051 PAINT AND COATINGS..........................................................................................1053 ANTI-CORROSION TREATMENT................................................................................1053 SEALANT APPLICATION AREAS...............................................................................1054 UNDER COATING APPLICATION AREAS.........................................................................1061 ANTI-CORROSION COMPOUND APPLICATION AREA................................................................1063 REQUIRED SERVICE MATERIAL...................................................................................1064 SECTION 10......................................................................................................1066 GENERAL DESCRIPTION.........................................................................................1067 SYSTEM SPECIFICATION....................................................................................1068 SEAT BELT PRETENSIONER (IF EQUIPPED)....................................................................1068 DIAGNOSIS...................................................................................................1068 INSPECTION AND REPAIR REQUIRED AFTER ACCIDENT...........................................................1068 ON-VEHICLE SERVICE..........................................................................................1069 SERVICE PRECAUTIONS.....................................................................................1069 SERVICE AND DIAGNOSIS...............................................................................1069 DISABLING AIR BAG SYSTEM............................................................................1069 ENABLING AIR BAG SYSTEM.............................................................................1069 HANDLING AND STORAGE................................................................................1069 DISPOSAL............................................................................................1069 FRONT SEAT BELT.........................................................................................1070 REAR SEAT BELT..........................................................................................1073 SECTION 10B.....................................................................................................1074 GENERAL DESCRIPTION.........................................................................................1076 SYSTEM COMPONENTS AND WIRING LOCATION VIEW AND CONNECTORS...............................................1077 SYSTEM WIRING DIAGRAM...................................................................................1078 DIAGNOSIS...................................................................................................1079 DIAGNOSTIC TROUBLE CODE (DTC)...........................................................................1079 USE OF SPECIAL TOOL.....................................................................................1079 INTERMITTENTS AND POOR CONNECTIONS......................................................................1081 AIR BAG DIAGNOSTIC SYSTEM CHECK.........................................................................1082 AIR BAG DIAGNOSTIC SYSTEM CHECK FLOW TABLE..............................................................1083 DTC CHECK...............................................................................................1084 DTC CLEARANCE...........................................................................................1085 DTC TABLE...............................................................................................1086 TABLE A - “AIR BAG” WARNING LAMP COMES ON STEADY........................................................1088 TABLE B - “AIR BAG” WARNING LAMP DOES NOT COME ON.......................................................1088 TABLE C - “AIR BAG” WARNING LAMP FLASHES................................................................1088 TABLE D - “AIR BAG” WARNING LAMP CANNOT INDICATE FLASHING PATTERN OF DTC................................1088 TABLE E - SDM CANNOT COMMUNICATE THROUGH THE SERIAL DATA CIRCUIT........................................1094 DTC B1015 - PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH.........................................1096 DTC B1016 - PASSENGER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW..........................................1096 DTC B1018 - PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND.........................................1096 DTC B1019 - PASSENGER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT..................................1096 DTC B1021 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE HIGH............................................1102 DTC B1022 – DRIVER AIR BAG INITIATOR CIRCUIT RESISTANCE LOW.............................................1102 DTC B1024 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO GROUND............................................1102 DTC B1025 – DRIVER AIR BAG INITIATOR CIRCUIT SHORT TO POWER CIRCUIT.....................................1102 DTC B1032 – POWER SOURCE VOLTAGE LOW....................................................................1109 DTC B1041 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH.......................................1111 DTC B1042 – DRIVER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW........................................1111 DTC B1043 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND.......................................1111 DTC B1044 – DRIVER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT................................1111 DTC B1045 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE HIGH....................................1111 DTC B1046 – PASSENGER PRETENSIONER INITIATOR CIRCUIT RESISTANCE LOW.....................................1111 DTC B1047 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO GROUND....................................1111 DTC B1048 – PASSENGER PRETENSIONER INITIATOR CIRCUIT SHORT TO POWER CIRCUIT.............................1111 DTC B1051 – FRONTAL CRASH DETECTED (SYSTEM ACTIVATION COMMAND OUTPUTTED)................................1117 DTC B1071 - INTERNAL SDM FAULT..........................................................................1118 DTC B1013 – SYSTEM SPECIFICATIONS DIFFERENT FROM SDM SPECIFICATIONS.....................................1118 ON-VEHICLE SERVICE..........................................................................................1119 SERVICE PRECAUTIONS.....................................................................................1119 SERVICE AND DIAGNOSIS...............................................................................1119 DISABLING AIR BAG SYSTEM............................................................................1120 ENABLING AIR BAG SYSTEM.............................................................................1120 HANDLING AND STORAGE................................................................................1121 REPAIRS AND INSPECTIONS REQUIRED AFTER AN ACCIDENT......................................................1126 ACCIDENT WITH DEPLOYMENT/ACTIVATION - COMPONENT REPLACEMENT.............................................1126 ACCIDENT WITH OR WITHOUT DEPLOYMENT/ACTIVATION - COMPONENT INSPECTIONS..................................1126 SDM.....................................................................................................1129 DRIVER AIR BAG (INFLATOR) MODULE........................................................................1132 CONTACT COIL AND COMBINATION SWITCH ASSEMBLY............................................................1132 SEAT BELT PRETENSIONER (IF EQUIPPED)....................................................................1132 AIR BAG (INFLATOR) MODULE AND SEAT BELT PRETENSIONER DISPOSAL...............................................1133 DEPLOYMENT/ACTIVATION OUTSIDE VEHICLE...................................................................1134 DEPLOYMENT/ACTIVATION INSIDE VEHICLE....................................................................1140 DEPLOYED AIR BAG (INFLATOR) MODULE AND ACTIVATED SEAT BELT PRETENSIONER DISPOSAL........................1143 SPECIAL TOOL................................................................................................1144 COPYRIGHT.......................................................................................................1146 BOOKCOVER....................................................................................................... 0
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