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SUZUKI RH413 RH416 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
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“Suzuki RH413 RH416 Liana Service Manual Vol 1 & 2” offers comprehensive instructions for maintenance and repair, ensuring meticulous care for optimal performance and longevity of these specific models.
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Description
SUZUKI RH413 RH416 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RH413 RH416 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
Language : English
Pages : 1304
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI RH413 RH416 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
Bookcover_vol1....................................................................................................................................................................................... 1 Bookcover_vol2....................................................................................................................................................................................... 2 99500_54G10_01E...................................................................................................................................................................................... 3 IMPORTANT........................................................................................................................................................................................ 3 FOREWORD......................................................................................................................................................................................... 5 TABLE OF CONTENTS................................................................................................................................................................................ 7 Precautions...................................................................................................................................................................................... 9 Precautions.................................................................................................................................................................................. 10 Precautions.............................................................................................................................................................................. 10 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System..................................................................................................... 10 General Precautions.................................................................................................................................................................. 13 Precautions for Catalytic Converter.................................................................................................................................................. 15 Precautions for Electrical Circuit Service........................................................................................................................................... 16 Precautions for Installing Mobile Communication Equipment............................................................................................................................ 18 Precautions for Vehicle Tie-Down Hooks............................................................................................................................................... 18 Precautions in Servicing Full-Time 4WD Vehicle....................................................................................................................................... 19 Air Bag Warning...................................................................................................................................................................... 20 Air Bag System Service Warning....................................................................................................................................................... 20 Fastener Caution..................................................................................................................................................................... 20 Suspension Caution................................................................................................................................................................... 20 Wheels and Tires Note................................................................................................................................................................ 20 Brake Note........................................................................................................................................................................... 21 Repair Instructions...................................................................................................................................................................... 21 Electrical Circuit Inspection Procedure.............................................................................................................................................. 21 Intermittent and Poor Connection Inspection.......................................................................................................................................... 23 General Information.............................................................................................................................................................................. 25 General Information.......................................................................................................................................................................... 26 General Description...................................................................................................................................................................... 26 Abbreviations........................................................................................................................................................................ 26 Symbols.............................................................................................................................................................................. 27 Wire Color Symbols................................................................................................................................................................... 28 Fasteners Information................................................................................................................................................................ 28 Vehicle Lifting Points............................................................................................................................................................... 30 Vehicle Identification Number........................................................................................................................................................ 32 Engine Identification Number......................................................................................................................................................... 32 Transmission Identification Number................................................................................................................................................... 32 Component Location....................................................................................................................................................................... 33 Warning, Caution and Information Labels Location..................................................................................................................................... 33 Maintenance and Lubrication.................................................................................................................................................................. 35 Precautions.............................................................................................................................................................................. 35 Precautions for Maintenance and Lubrication.......................................................................................................................................... 35 Scheduled Maintenance.................................................................................................................................................................... 35 Normal Condition Schedule............................................................................................................................................................ 35 Maintenance Recommended under Severe Driving Conditions.............................................................................................................................. 36 Repair Instructions...................................................................................................................................................................... 37 Drive Belt Inspection................................................................................................................................................................ 37 Drive Belt Replacement............................................................................................................................................................... 38 Valve Lash (Clearance) Inspection.................................................................................................................................................... 38 Engine Oil and Filter Change......................................................................................................................................................... 38 Engine Coolant Change................................................................................................................................................................ 39 Exhaust System Inspection............................................................................................................................................................ 39 Spark Plugs Replacement.............................................................................................................................................................. 40 Air Cleaner Filter Inspection........................................................................................................................................................ 40 Air Cleaner Filter Replacement....................................................................................................................................................... 40 Fuel Lines and Connections Inspection................................................................................................................................................ 40 Fuel Filter Replacement.............................................................................................................................................................. 40 Fuel Tank Inspection................................................................................................................................................................. 41 PCV Valve Inspection................................................................................................................................................................. 41 Fuel Evaporative Emission Control System Inspection.................................................................................................................................. 41 Brake Discs and Pads (Front) Inspection.............................................................................................................................................. 41 Brake Drums and Shoes (Rear) Inspection.............................................................................................................................................. 41 Brake Hoses and Pipes Inspection..................................................................................................................................................... 41 Brake Fluid Replacement.............................................................................................................................................................. 41 Brake Lever and Cable Inspection..................................................................................................................................................... 42 Clutch Fluid Inspection.............................................................................................................................................................. 42 Tires / Wheels Inspection............................................................................................................................................................ 42 Wheel Discs Inspection............................................................................................................................................................... 42 Wheel Bearing Inspection............................................................................................................................................................. 42 Suspension System Inspection......................................................................................................................................................... 43 Steering System Inspection........................................................................................................................................................... 43 Drive Shaft (Axle) Boots Inspection.................................................................................................................................................. 44 Propeller Shafts (4WD) Inspection.................................................................................................................................................... 44 Manual Transaxle Oil Inspection...................................................................................................................................................... 44 Manual Transaxle Oil Replacement..................................................................................................................................................... 44 Automatic Transaxle Fluid Inspection................................................................................................................................................. 45 Automatic Transaxle Fluid Replacement................................................................................................................................................ 45 Automatic Transaxle Fluid Cooler Hose Inspection..................................................................................................................................... 45 Transfer Oil (4WD A/T) and Rear Differential Oil (4WD) Inspection.................................................................................................................... 45 Transfer Oil (4WD A/T) and Rear Differential Oil (4WD) Replacement................................................................................................................... 46 All Latches, Hinges and Locks Inspection............................................................................................................................................. 46 Power Steering (P/S) System Inspection............................................................................................................................................... 46 Final Inspection for Maintenance Service............................................................................................................................................. 47 Specifications........................................................................................................................................................................... 48 Tightening Torque Specifications..................................................................................................................................................... 48 Special Tools and Equipment.............................................................................................................................................................. 48 Recommended Fluids and Lubricants.................................................................................................................................................... 48 Special Tool......................................................................................................................................................................... 48 Engine........................................................................................................................................................................................... 49 Precautions.................................................................................................................................................................................. 53 Precautions.............................................................................................................................................................................. 53 Precautions for Engine............................................................................................................................................................... 53 Engine General Information and Diagnosis..................................................................................................................................................... 54 Precautions.............................................................................................................................................................................. 54 Precautions on Engine Service........................................................................................................................................................ 54 Precautions in Diagnosing Trouble.................................................................................................................................................... 54 General Description...................................................................................................................................................................... 54 Statement on Cleanliness and Care.................................................................................................................................................... 54 Engine Diagnosis General Description................................................................................................................................................. 55 On-Board Diagnostic System Description............................................................................................................................................... 55 Engine and Emission Control System Description....................................................................................................................................... 58 Air Intake System Description........................................................................................................................................................ 59 Electronic Control System Description................................................................................................................................................ 59 Engine and Emission Control Input / Output Table..................................................................................................................................... 64 Schematic and Routing Diagram............................................................................................................................................................ 65 Engine and Emission Control System Diagram........................................................................................................................................... 65 Component Location....................................................................................................................................................................... 67 Electronic Control System Components Location........................................................................................................................................ 67 Diagnostic Information and Procedures.................................................................................................................................................... 69 Engine and Emission Control System Check............................................................................................................................................. 69 Malfunction Indicator Lamp (MIL) Check............................................................................................................................................... 72 DTC Check............................................................................................................................................................................ 73 DTC Clearance........................................................................................................................................................................ 73 DTC Table............................................................................................................................................................................ 74 Fail-Safe Table...................................................................................................................................................................... 77 Scan Tool Data....................................................................................................................................................................... 78 Visual Inspection.................................................................................................................................................................... 82 Engine Basic Inspection.............................................................................................................................................................. 82 Engine Symptom Diagnosis............................................................................................................................................................. 86 Malfunction Indicator Lamp Does Not Come ON at Ignition Switch ON (But Engine at Stop)............................................................................................... 92 Malfunction Indicator Lamp Remains ON after Engine Starts............................................................................................................................ 94 MIL Flashes at Ignition Switch ON (Vehicle without Immobilizer Indicator Lamp)....................................................................................................... 95 MIL Does Not Flash or Just Remains ON Even with Grounding Diagnosis Switch Terminal (Vehicle without Immobilizer Indicator Lamp)..................................................... 96 MIL Does Not Light at Ignition Switch ON and Engine Does Not Start Through It Is Cranked Up.......................................................................................... 97 DTC P0105 (No. 11): Manifold Absolute Pressure (MAP) Circuit Malfunction............................................................................................................. 99 DTC P0110 (No. 18): Intake Air Temp. (IAT) Circuit Malfunction....................................................................................................................... 101 DTC P0115 (No. 19): Engine Coolant Temp. (ECT) Circuit Malfunction................................................................................................................... 103 DTC P0120 (No. 13): Throttle Position Circuit Malfunction............................................................................................................................ 105 DTC P0121: Throttle Position Circuit Range / Performance Problem..................................................................................................................... 107 DTC P0130 (No. 14): Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)....................................................................................................... 109 DTC P0133: Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1).............................................................................................................. 111 DTC P0134: Heated Oxygen Sensor (HO2S) Circuit No Activity Detected (Sensor-1)....................................................................................................... 112 DTC P0135 (No. 14): Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1)................................................................................................ 113 DTC P0136: Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)................................................................................................................ 115 DTC P0141: Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2)......................................................................................................... 117 DTC P0171 / P0172: Fuel System Too Lean / Rich....................................................................................................................................... 119 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected (Misfire Detected at 2 or More Cylinders) / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected.... 124 DTC P0325 (No. 17): Knock Sensor Circuit Malfunction................................................................................................................................. 129 DTC P0335 (No. 23): Crankshaft Position (CKP) Sensor Circuit Malfunction............................................................................................................. 131 DTC P0340 (No. 15): Camshaft Position (CMP) Sensor Circuit Malfunction............................................................................................................... 134 DTC P0400: Exhaust Gas Recirculation Flow Malfunction................................................................................................................................ 137 DTC P0420: Catalyst System Efficiency below Threshold................................................................................................................................ 140 DTC P0443: Purge Control Valve Circuit Malfunction................................................................................................................................... 142 DTC P0480: Radiator Cooling Fan Control System Malfunction........................................................................................................................... 143 DTC P0500 (No. 16): Vehicle Speed Sensor (VSS) Malfunction........................................................................................................................... 146 DTC P0505: Idle Control System Malfunction........................................................................................................................................... 150 DTC P0601: Internal Control Module Memory Check Sum Error............................................................................................................................ 152 DTC P1450 (No.29) / P1451: Barometric Pressure Sensor Low / High Input / Performance Problem......................................................................................... 152 DTC P1500: Engine Starter Signal Circuit Malfunction................................................................................................................................. 153 DTC P1510: ECM Back-Up Power Supply Malfunction...................................................................................................................................... 155 DTC P1600: Serial Communication Problem between ECM and TCM.......................................................................................................................... 156 DTC P1717: A/T Drive Range (Park/Neutral Position) Signal Circuit Malfunction........................................................................................................ 158 Inspection of ECM and Its Circuits................................................................................................................................................... 161 Fuel Injector Circuit Check.......................................................................................................................................................... 174 Fuel Pump and Its Circuit Check...................................................................................................................................................... 175 Fuel Pressure Check.................................................................................................................................................................. 177 Idle Air Control System Check........................................................................................................................................................ 179 Throttle Valve Opening Signal Inspection............................................................................................................................................. 181 A/C Control System Check (Vehicle with A/C).......................................................................................................................................... 182 Electric Load Signal Circuit Check................................................................................................................................................... 186 Radiator Fan Control System Check.................................................................................................................................................... 187 Power Steering Pressure (PSP) Switch Signal Circuit Check............................................................................................................................ 189 Generator Control Signal Circuit Check............................................................................................................................................... 191 Repair Instructions...................................................................................................................................................................... 192 Idle Speed / Idle Air Control (IAC) Duty Inspection.................................................................................................................................. 192 Idle Mixture Inspection / Adjustment (Vehicle without Heated Oxygen Sensor).......................................................................................................... 193 Special Tools and Equipment.............................................................................................................................................................. 194 Special Tool......................................................................................................................................................................... 194 Aux. Emission Control Devices................................................................................................................................................................ 195 Diagnostic Information and Procedures.................................................................................................................................................... 195 EGR System Inspection (Using SUZUKI Scan Tool)....................................................................................................................................... 195 Repair Instructions...................................................................................................................................................................... 195 EVAP Canister Inspection............................................................................................................................................................. 195 EVAP Canister Purge Inspection....................................................................................................................................................... 195 EVAP Canister Purge Valve and Its Circuit Inspection................................................................................................................................. 196 EVAP Canister Purge Valve Inspection................................................................................................................................................. 197 Vacuum Passage Inspection............................................................................................................................................................ 198 Vacuum Hose Inspection............................................................................................................................................................... 198 EGR Valve Removal and Installation................................................................................................................................................... 198 EGR Valve Inspection................................................................................................................................................................. 198 PCV Hose Inspection.................................................................................................................................................................. 198 PCV Valve Inspection................................................................................................................................................................. 199 Special Tools and Equipment.............................................................................................................................................................. 199 Special Tool......................................................................................................................................................................... 199 Engine Electrical Devices.................................................................................................................................................................... 200 Repair Instructions...................................................................................................................................................................... 200 Idle Air Control (IAC) Valve Removal and Installation................................................................................................................................ 200 Idle Air Control (IAC) Valve Inspection.............................................................................................................................................. 200 Engine Control Module (ECM) Removal and Installation................................................................................................................................. 201 Manifold Absolute Pressure (MAP) Sensor Inspection................................................................................................................................... 201 Throttle Position (TP) Sensor On-Vehicle Inspection.................................................................................................................................. 202 Throttle Position (TP) Sensor Removal and Installation............................................................................................................................... 202 Intake Air Temperature (IAT) Sensor Removal and Installation......................................................................................................................... 202 Intake Air Temperature (IAT) Sensor Inspection....................................................................................................................................... 203 Engine Coolant Temperature (ECT) Sensor Removal and Installation..................................................................................................................... 203 Engine Coolant Temperature (ECT) Sensor Inspection................................................................................................................................... 204 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation.................................................................................................................... 204 Oxygen Sensor Heater Inspection...................................................................................................................................................... 205 Camshaft Position (CMP) Sensor Removal and Installation.............................................................................................................................. 205 Camshaft Position (CMP) Sensor and Its Circuit Inspection............................................................................................................................ 205 Crankshaft Position (CKP) Sensor Removal and Installation............................................................................................................................ 205 Crankshaft Position (CKP) Sensor and Its Circuit Inspection.......................................................................................................................... 206 Vehicle Speed Sensor (VSS) and Its Circuit Inspection................................................................................................................................ 206 Main Relay, Fuel Pump Relay, A/C Compressor Relay and A/C Condenser Fan Relay Inspection............................................................................................. 206 Radiator Fan Relay No.1, No.2 and No.3 Inspection.................................................................................................................................... 207 Specifications........................................................................................................................................................................... 207 Tightening Torque Specifications..................................................................................................................................................... 207 Engine Mechanical............................................................................................................................................................................ 208 General Description...................................................................................................................................................................... 208 Engine Construction Description...................................................................................................................................................... 208 Diagnostic Information and Procedures.................................................................................................................................................... 209 Compression Check.................................................................................................................................................................... 209 Engine Vacuum Check.................................................................................................................................................................. 210 Valve Lash (Clearance) Inspection.................................................................................................................................................... 210 Repair Instructions...................................................................................................................................................................... 213 Air Cleaner Element Removal and Installation......................................................................................................................................... 213 Air Cleaner Element Inspection and Cleaning.......................................................................................................................................... 213 Accelerator Cable Adjustment......................................................................................................................................................... 214 Throttle Body Components............................................................................................................................................................. 214 Throttle Body On-Vehicle Inspection.................................................................................................................................................. 214 Throttle Body Removal and Installation............................................................................................................................................... 214 Throttle Body Disassembly and Assembly............................................................................................................................................... 215 Throttle Body Cleaning............................................................................................................................................................... 215 Throttle Body and Intake Manifold Components......................................................................................................................................... 216 Throttle Body and Intake Manifold Removal and Installation........................................................................................................................... 216 Cylinder Head Cover Removal and Installation......................................................................................................................................... 218 Engine Mountings Components.......................................................................................................................................................... 220 Engine Assembly Removal and Installation............................................................................................................................................. 220 Timing Chain Cover Components........................................................................................................................................................ 224 Timing Chain Cover Removal and Installation.......................................................................................................................................... 224 Timing Chain Cover Cleaning and Inspection........................................................................................................................................... 226 Timing Chain and Chain Tensioner Components.......................................................................................................................................... 226 Timing Chain and Chain Tensioner Removal and Installation............................................................................................................................ 227 Timing Chain and Chain Tensioner Inspection.......................................................................................................................................... 229 Camshaft, Tappet and Shim Components................................................................................................................................................. 230 Camshaft, Tappet and Shim Removal and installation................................................................................................................................... 230 Camshaft, Tappet and shim Inspection................................................................................................................................................. 232 Valves and Cylinder Head Components.................................................................................................................................................. 234 Valves and Cylinder Head Removal and Installation.................................................................................................................................... 235 Valves and Cylinder Head Disassembly and Assembly.................................................................................................................................... 237 Valves and Valve Guides Inspection................................................................................................................................................... 239 Cylinder Head Inspection............................................................................................................................................................. 241 Valve Spring Inspection.............................................................................................................................................................. 242 Pistons, Piston Rings and Connecting Rods Components................................................................................................................................. 243 Pistons, Piston Rings and Connecting Rods Removal and Installation................................................................................................................... 243 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly........................................................................................................ 244 Cylinders, Pistons and Piston Rings Inspection....................................................................................................................................... 245 Piston Pins and Connecting Rods Inspection........................................................................................................................................... 247 Crank Pin and Connecting Rod Bearings Inspection..................................................................................................................................... 248 Main Bearings, Crankshaft and Cylinder Block Components.............................................................................................................................. 252 Main Bearings, Crankshaft and Cylinder Block Removal and Installation................................................................................................................ 253 Crankshaft Inspection................................................................................................................................................................ 256 Main Bearings Inspection............................................................................................................................................................. 257 Sensor Plate Inspection.............................................................................................................................................................. 261 Rear Oil Seal Inspection............................................................................................................................................................. 262 Flywheel Inspection.................................................................................................................................................................. 262 Cylinder Block Inspection............................................................................................................................................................ 262 Specifications........................................................................................................................................................................... 263 Tightening Torque Specifications..................................................................................................................................................... 263 Special Tools and Equipment.............................................................................................................................................................. 264 Recommended Service Material......................................................................................................................................................... 264 Special Tool......................................................................................................................................................................... 264 Engine Lubrication System.................................................................................................................................................................... 266 General Description...................................................................................................................................................................... 266 Engine Lubrication Description....................................................................................................................................................... 266 Diagnostic Information and Procedures.................................................................................................................................................... 267 Oil Pressure Check................................................................................................................................................................... 267 Repair Instructions...................................................................................................................................................................... 268 Oil Pan and Oil Pump Strainer Components............................................................................................................................................. 268 Oil Pan and Oil Pump Strainer Removal and Installation............................................................................................................................... 268 Oil Pan and Oil Pump Strainer Cleaning............................................................................................................................................... 270 Oil Pump Components.................................................................................................................................................................. 270 Oil Pump Removal and Installation.................................................................................................................................................... 271 Oil Pump Disassembly and Assembly.................................................................................................................................................... 271 Oil Pump Inspection.................................................................................................................................................................. 272 Specifications........................................................................................................................................................................... 273 Tightening Torque Specifications..................................................................................................................................................... 273 Special Tools and Equipment.............................................................................................................................................................. 273 Recommended Service Material......................................................................................................................................................... 273 Special Tool......................................................................................................................................................................... 273 Engine Cooling System........................................................................................................................................................................ 274 General Description...................................................................................................................................................................... 274 Cooling System Description........................................................................................................................................................... 274 Coolant Description.................................................................................................................................................................. 274 Schematic and Routing Diagram............................................................................................................................................................ 275 Coolant Circulation.................................................................................................................................................................. 275 Diagnostic Information and Procedures.................................................................................................................................................... 276 Engine Cooling Symptom Diagnosis..................................................................................................................................................... 276 Repair Instructions...................................................................................................................................................................... 277 Cooling System Components............................................................................................................................................................ 277 Coolant Level Check.................................................................................................................................................................. 278 Engine Cooling System Inspection and Cleaning........................................................................................................................................ 278 Cooling System Flush and Refill...................................................................................................................................................... 279 Cooling Water Pipes or Hoses Removal and Installation................................................................................................................................ 279 Thermostat Removal and Installation.................................................................................................................................................. 280 Thermostat Inspection................................................................................................................................................................ 280 Water Valve (If Equipped) Removal and Installation................................................................................................................................... 281 Water Valve (If Equipped) Inspection................................................................................................................................................. 281 Radiator Cooling Fan On-Vehicle Inspection........................................................................................................................................... 281 Radiator Cooling Fan Relay Inspection................................................................................................................................................ 282 Radiator Cooling Fan Removal and Installation........................................................................................................................................ 282 Radiator On-Vehicle Inspection and Cleaning.......................................................................................................................................... 283 Radiator Removal and Installation.................................................................................................................................................... 283 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.................................................................................................................. 283 Water Pump / Generator Drive Belt Removal and Installation........................................................................................................................... 284 Water Pump Removal and Installation.................................................................................................................................................. 284 Water Pump Inspection................................................................................................................................................................ 285 Specifications........................................................................................................................................................................... 286 Tightening Torque Specifications..................................................................................................................................................... 286 Special Tools and Equipment.............................................................................................................................................................. 286 Recommended Service Material......................................................................................................................................................... 286 Special Tool......................................................................................................................................................................... 286 Fuel System.................................................................................................................................................................................. 287 Precautions.............................................................................................................................................................................. 287 Precautions on Fuel System Service................................................................................................................................................... 287 General Description...................................................................................................................................................................... 288 Fuel System Description.............................................................................................................................................................. 288 Fuel Delivery System Description..................................................................................................................................................... 288 Fuel Pump Description................................................................................................................................................................ 288 Schematic and Routing Diagram............................................................................................................................................................ 289 Fuel Delivery System Diagram......................................................................................................................................................... 289 Diagnostic Information and Procedures.................................................................................................................................................... 289 Fuel Pressure Inspection............................................................................................................................................................. 289 Fuel Cut Operation Inspection........................................................................................................................................................ 290 Repair Instructions...................................................................................................................................................................... 291 Fuel System Components............................................................................................................................................................... 291 Fuel Pressure Relief Procedure....................................................................................................................................................... 292 Fuel Leakage Check Procedure......................................................................................................................................................... 292 Fuel Lines On-Vehicle Inspection..................................................................................................................................................... 292 Fuel Pipe Removal and Installation................................................................................................................................................... 292 Fuel Injector On-Vehicle Inspection.................................................................................................................................................. 293 Fuel Injector Removal and Installation............................................................................................................................................... 294 Fuel Injector Inspection............................................................................................................................................................. 294 Fuel Pressure Regulator On-Vehicle Inspection........................................................................................................................................ 296 Fuel Pressure Regulator Removal and Installation..................................................................................................................................... 296 Fuel Filler Cap Inspection........................................................................................................................................................... 296 Fuel Tank Removal and Installation................................................................................................................................................... 297 Fuel Tank Inspection................................................................................................................................................................. 299 Fuel Tank Purging Procedure.......................................................................................................................................................... 299 Fuel Tank Inlet Valve Removal and Installation....................................................................................................................................... 299 Fuel Tank Inlet Valve Inspection..................................................................................................................................................... 300 Fuel Pump On-Vehicle Inspection...................................................................................................................................................... 300 Fuel Pump Assembly Components........................................................................................................................................................ 300 Fuel Pump Assembly Removal and Installation.......................................................................................................................................... 301 Fuel Pump Assembly Disassembly and Assembly.......................................................................................................................................... 302 Fuel Pump Assembly Inspection........................................................................................................................................................ 302 Specifications........................................................................................................................................................................... 303 Tightening Torque Specifications..................................................................................................................................................... 303 Special Tools and Equipment.............................................................................................................................................................. 303 Recommended Service Material......................................................................................................................................................... 303 Special Tool......................................................................................................................................................................... 303 Ignition System.............................................................................................................................................................................. 305 General Description...................................................................................................................................................................... 305 Ignition System Construction......................................................................................................................................................... 305 Schematic and Routing Diagram............................................................................................................................................................ 306 Ignition System Wiring Circuit Diagram............................................................................................................................................... 306 Component Location....................................................................................................................................................................... 307 Ignition System Components Location.................................................................................................................................................. 307 Diagnostic Information and Procedures.................................................................................................................................................... 308 Ignition System Symptom Diagnosis.................................................................................................................................................... 308 Ignition System Check................................................................................................................................................................ 308 Ignition Spark Test.................................................................................................................................................................. 309 Repair Instructions...................................................................................................................................................................... 310 High-Tension Cord Removal and Installation........................................................................................................................................... 310 High-Tension Cord Inspection......................................................................................................................................................... 310 Spark Plug Removal and Installation.................................................................................................................................................. 311 Spark Plug Inspection................................................................................................................................................................ 311 Ignition Coil Assembly (Including Igniter) Removal and Installation.................................................................................................................. 311 Ignition Coil Assembly (Including Igniter) Inspection................................................................................................................................ 312 Ignition Timing Inspection........................................................................................................................................................... 312 Specifications........................................................................................................................................................................... 313 Tightening Torque Specifications..................................................................................................................................................... 313 Special Tools and Equipment.............................................................................................................................................................. 313 Special Tool......................................................................................................................................................................... 313 Starting System.............................................................................................................................................................................. 314 Schematic and Routing Diagram............................................................................................................................................................ 314 Cranking System Circuit Diagram...................................................................................................................................................... 314 Diagnostic Information and Procedures.................................................................................................................................................... 314 Cranking System Symptom Diagnosis.................................................................................................................................................... 314 Cranking System Test................................................................................................................................................................. 316 Repair Instructions...................................................................................................................................................................... 317 Starting Motor Dismounting and Remounting............................................................................................................................................ 317 Starting Motor Components............................................................................................................................................................ 318 Starting Motor Inspection............................................................................................................................................................ 320 Specifications........................................................................................................................................................................... 323 Cranking System Specifications....................................................................................................................................................... 323 Tightening Torque Specifications..................................................................................................................................................... 324 Special Tools and Equipment.............................................................................................................................................................. 324 Recommended Service Material......................................................................................................................................................... 324 Charging System.............................................................................................................................................................................. 325 General Description...................................................................................................................................................................... 325 Battery Description.................................................................................................................................................................. 325 Generator Description................................................................................................................................................................ 326 Diagnostic Information and Procedures.................................................................................................................................................... 327 Battery Inspection................................................................................................................................................................... 327 Generator Symptom Diagnosis.......................................................................................................................................................... 328 Generator Test (Undercharged Battery Check).......................................................................................................................................... 328 Generator Test (Overcharged Battery Check)........................................................................................................................................... 329 Repair Instructions...................................................................................................................................................................... 330 Jump Starting in Case of Emergency................................................................................................................................................... 330 Battery Dismounting and Remounting................................................................................................................................................... 330 Generator Dismounting and Remounting................................................................................................................................................. 331 Generator Components................................................................................................................................................................. 332 Generator Inspection................................................................................................................................................................. 332 Specifications........................................................................................................................................................................... 334 Charging System Specifications....................................................................................................................................................... 334 Tightening Torque Specifications..................................................................................................................................................... 334 Exhaust System............................................................................................................................................................................... 335 General Description...................................................................................................................................................................... 335 Exhaust System Description........................................................................................................................................................... 335 Repair Instructions...................................................................................................................................................................... 335 Exhaust System Components............................................................................................................................................................ 335 Exhaust Manifold Components.......................................................................................................................................................... 336 Exhaust Manifold Removal and Installation............................................................................................................................................ 336 Exhaust Pipe Removal and Installation................................................................................................................................................ 337 Specifications........................................................................................................................................................................... 337 Tightening Torque Specifications..................................................................................................................................................... 337 Suspension....................................................................................................................................................................................... 339 Precautions.................................................................................................................................................................................. 341 Precautions.............................................................................................................................................................................. 341 Precautions on Suspension............................................................................................................................................................ 341 Suspension General Diagnosis................................................................................................................................................................. 342 Diagnostic Information and Procedures.................................................................................................................................................... 342 Suspension, Wheels and Tires Symptom Diagnosis....................................................................................................................................... 342 Specifications........................................................................................................................................................................... 344 Wheel Alignment Specifications....................................................................................................................................................... 344 Front Suspension............................................................................................................................................................................. 345 General Description...................................................................................................................................................................... 345 Front Suspension Construction........................................................................................................................................................ 345 Front Wheel Alignment Construction................................................................................................................................................... 346 Repair Instructions...................................................................................................................................................................... 346 Front Wheel Alignment Inspection and Adjustment...................................................................................................................................... 346 Front Stabilizer Bar and/or Bushings Components...................................................................................................................................... 348 Front Stabilizer Bar and/or Bushings Removal and Installation........................................................................................................................ 348 Front Stabilizer Bar, Bushing and/or Joint Check..................................................................................................................................... 349 Front Strut Assembly Components...................................................................................................................................................... 350 Front Strut Assembly Removal and Installation........................................................................................................................................ 351 Front Strut Assembly Disassembly and Assembly........................................................................................................................................ 353 Front Strut Assembly Check........................................................................................................................................................... 354 Front Wheel Hub and Steering Knuckle Components...................................................................................................................................... 355 Front Wheel Hub and Steering Knuckle Removal and Installation........................................................................................................................ 355 Front Wheel Hub and Steering Knuckle Disassembly and Assembly........................................................................................................................ 358 Front Wheel Disc, Nut and Bearing Check.............................................................................................................................................. 359 Suspension Control Arm / Bushing Removal and Installation............................................................................................................................ 360 Suspension Control Arm / Bushing Disassembly and Assembly............................................................................................................................ 361 Suspension Control Arm / Steering Knuckle Check...................................................................................................................................... 361 Suspension Control Arm Bushing Check................................................................................................................................................. 361 Suspension Control Arm Joint Check................................................................................................................................................... 362 Front Suspension Frame Components.................................................................................................................................................... 362 Front Suspension Frame Removal and Installation...................................................................................................................................... 363 Front Suspension Frame Check......................................................................................................................................................... 364 Front Suspension Fasteners Check..................................................................................................................................................... 364 Specifications........................................................................................................................................................................... 365 Tightening Torque Specifications..................................................................................................................................................... 365 Special Tools and Equipment.............................................................................................................................................................. 366 Special Tool......................................................................................................................................................................... 366 Rear Suspension.............................................................................................................................................................................. 367 General Description...................................................................................................................................................................... 367 Rear Suspension Construction......................................................................................................................................................... 367 Rear Wheel Alignment Construction.................................................................................................................................................... 369 Repair Instructions...................................................................................................................................................................... 369 Rear Wheel Alignment Inspection and Adjustment....................................................................................................................................... 369 Rear Stabilizer Bar and/or Bushings Components....................................................................................................................................... 370 Rear Stabilizer Bar and/or Bushings Removal and Installation......................................................................................................................... 371 Rear Stabilizer Bar, Bushing and/or Joint Check...................................................................................................................................... 371 Rear Strut Assembly Components....................................................................................................................................................... 372 Rear Strut Assembly Removal and Installation......................................................................................................................................... 373 Rear Strut Assembly Disassembly and Assembly......................................................................................................................................... 374 Rear Strut Assembly Check............................................................................................................................................................ 376 Control Rod Components............................................................................................................................................................... 376 Control Rod Removal and Installation................................................................................................................................................. 377 Control Rod Check.................................................................................................................................................................... 378 Trailing Rod Removal and Installation................................................................................................................................................ 378 Trailing Rod Check................................................................................................................................................................... 378 Rear Suspension Frame Components..................................................................................................................................................... 379 Rear Suspension Frame Removal and Installation (2WD Model)........................................................................................................................... 380 Rear Suspension Frame Removal and Installation (4WD Model)........................................................................................................................... 381 Rear Suspension Frame, Bushing and Pad Check......................................................................................................................................... 382 Wheel Hub with Wheel Bearing and Wheel Stud Removal and Installation (2WD Model)..................................................................................................... 382 Wheel Hub, Wheel Stud / Wheel Bearing Outside Inner Race Removal and Installation (4WD Model)........................................................................................ 383 Rear Wheel Hub, Wheel Bearing and Wheel Stud Inspection.............................................................................................................................. 385 Rear Wheel Disc, Nut and Bearing Check............................................................................................................................................... 385 Rear Knuckle Removal and Installation (2WD Model).................................................................................................................................... 386 Rear Knuckle, Wheel Bearing / Oil Seal Removal and Installation (4WD Model).......................................................................................................... 388 Rear Suspension Knuckle Check........................................................................................................................................................ 389 Rear Suspension Fasteners Check...................................................................................................................................................... 389 Specifications........................................................................................................................................................................... 390 Tightening Torque Specifications..................................................................................................................................................... 390 Special Tools and Equipment.............................................................................................................................................................. 390 Recommended Service Material......................................................................................................................................................... 390 Special Tool......................................................................................................................................................................... 391 Wheels and Tires............................................................................................................................................................................. 392 General Description...................................................................................................................................................................... 392 Tires Description.................................................................................................................................................................... 392 Wheels Description................................................................................................................................................................... 393 Irregular and/or Premature Wear Description.......................................................................................................................................... 394 Wear Indicators Description.......................................................................................................................................................... 394 Radial Tire Waddle Description....................................................................................................................................................... 394 Radial Tire Lead / Pull Description.................................................................................................................................................. 395 Balancing Wheels Description......................................................................................................................................................... 395 Repair Instructions...................................................................................................................................................................... 396 General Balance Procedures........................................................................................................................................................... 396 Tire Rotation........................................................................................................................................................................ 396 Wheel Removal and Installation....................................................................................................................................................... 397 Tire Mounting and Dismounting........................................................................................................................................................ 397 Tire Repair.......................................................................................................................................................................... 397 Specifications........................................................................................................................................................................... 398 Wheels and Tires Specifications...................................................................................................................................................... 398 Tightening Torque Specifications..................................................................................................................................................... 398 Driveline / Axle................................................................................................................................................................................. 399 Precautions.................................................................................................................................................................................. 401 Precautions.............................................................................................................................................................................. 401 Precautions on Driveline / Axle...................................................................................................................................................... 401 Drive Shaft / Axle........................................................................................................................................................................... 402 Front.................................................................................................................................................................................... 402 General Description.................................................................................................................................................................. 402 Front Drive Shaft Construction................................................................................................................................................... 402 Diagnostic Information and Procedures................................................................................................................................................ 402 Front Drive Shaft Symptom Diagnosis.............................................................................................................................................. 402 Repair Instructions.................................................................................................................................................................. 403 Front Drive Shaft Components..................................................................................................................................................... 403 Drive Shaft Boot On-Vehicle Inspection........................................................................................................................................... 404 Front Drive Shaft Assembly Removal and Installation.............................................................................................................................. 404 Front Drive Shaft Disassembly and Assembly....................................................................................................................................... 405 Specifications....................................................................................................................................................................... 412 Tightening Torque Specifications................................................................................................................................................. 412 Special Tools and Equipment.......................................................................................................................................................... 412 Recommended Service Material..................................................................................................................................................... 412 Special Tool..................................................................................................................................................................... 412 Rear..................................................................................................................................................................................... 413 General Description.................................................................................................................................................................. 413 Rear Drive Shaft Description..................................................................................................................................................... 413 Repair Instructions.................................................................................................................................................................. 413 Rear Drive Shaft Components...................................................................................................................................................... 413 Rear Drive Shaft Removal and Installation........................................................................................................................................ 413 Rear Drive Shaft Disassembly and Assembly........................................................................................................................................ 414 Specifications....................................................................................................................................................................... 415 Tightening Torque Specifications................................................................................................................................................. 415 Special Tools and Equipment.......................................................................................................................................................... 415 Recommended Service Material..................................................................................................................................................... 415 Differential................................................................................................................................................................................. 416 Precautions.............................................................................................................................................................................. 416 Precaution for Rear Differential Oil Leakage......................................................................................................................................... 416 General Description...................................................................................................................................................................... 416 Rear Differential Description........................................................................................................................................................ 416 Diagnostic Information and Procedures.................................................................................................................................................... 417 Rear Differential Symptom Diagnosis.................................................................................................................................................. 417 Repair Instructions...................................................................................................................................................................... 417 Rear Differential Oil Change......................................................................................................................................................... 417 Rear Differential Front Mounting Removal and Installation............................................................................................................................ 418 Rear Differential Rear Mounting Removal and Installation............................................................................................................................. 418 Rear Differential Assembly Dismounting and Remounting................................................................................................................................ 420 Rear Differential Components......................................................................................................................................................... 421 Rear Differential Disassembly and Assembly........................................................................................................................................... 422 Rear Differential Inspection......................................................................................................................................................... 429 Drive Bevel Pinion Shim Adjustment................................................................................................................................................... 430 Specifications........................................................................................................................................................................... 433 Tightening Torque Specifications..................................................................................................................................................... 433 Special Tools and Equipment.............................................................................................................................................................. 434 Recommended Service Material......................................................................................................................................................... 434 Special Tool......................................................................................................................................................................... 434 Transfer..................................................................................................................................................................................... 436 General Description...................................................................................................................................................................... 436 Transfer Description................................................................................................................................................................. 436 Diagnostic Information and Procedures.................................................................................................................................................... 437 Transfer Symptom Diagnosis........................................................................................................................................................... 437 Repair Instructions...................................................................................................................................................................... 437 Transfer Oil Change.................................................................................................................................................................. 437 Transfer Dismounting and Remounting.................................................................................................................................................. 437 Transfer Assembly Components......................................................................................................................................................... 440 Transfer Assembly Disassembly and Assembly........................................................................................................................................... 441 Reduction Drive Gear, Reduction Idler Gear and Reduction Driven Gear Disassembly and Assembly........................................................................................ 444 Transfer Right Case and Left Case Disassembly and Assembly........................................................................................................................... 445 Transfer Output Retainer Assembly Disassembly and Assembly........................................................................................................................... 446 Transfer Assembly Inspection......................................................................................................................................................... 450 Bevel Gear Tooth Contact Inspection.................................................................................................................................................. 450 Specifications........................................................................................................................................................................... 452 Tightening Torque Specifications..................................................................................................................................................... 452 Special Tools and Equipment.............................................................................................................................................................. 453 Recommended Service Material......................................................................................................................................................... 453 Special Tool......................................................................................................................................................................... 453 Propeller Shafts............................................................................................................................................................................. 455 General Description...................................................................................................................................................................... 455 Propeller Shaft Description.......................................................................................................................................................... 455 Repair Instructions...................................................................................................................................................................... 455 Propeller Shaft Components........................................................................................................................................................... 455 Propeller Shaft Removal and Installation............................................................................................................................................. 456 Propeller Shaft Inspection........................................................................................................................................................... 457 Specifications........................................................................................................................................................................... 457 Tightening Torque Specifications..................................................................................................................................................... 457 Brakes........................................................................................................................................................................................... 459 Brake Control System and Diagnosis........................................................................................................................................................... 461 Precautions.............................................................................................................................................................................. 461 Precautions on Brake................................................................................................................................................................. 461 General Description...................................................................................................................................................................... 461 Brakes Construction.................................................................................................................................................................. 461 Front Brake Hose / Pipe Construction................................................................................................................................................. 463 Rear Brake Hose / Pipe Construction.................................................................................................................................................. 466 Diagnostic Information and Procedures.................................................................................................................................................... 467 Brakes Diagnosis Note................................................................................................................................................................ 467 Brakes Symptom Diagnosis............................................................................................................................................................. 467 Fluid Pressure Test (If Equipped with LSPV).......................................................................................................................................... 469 Repair Instructions...................................................................................................................................................................... 471 Brake Pedal Free Height Inspection................................................................................................................................................... 471 Brake Pedal Play Inspection.......................................................................................................................................................... 471 Excessive Pedal Travel Inspection.................................................................................................................................................... 471 Master Cylinder and Brake Fluid Level Inspection..................................................................................................................................... 472 Stop Light Switch Adjustment......................................................................................................................................................... 472 Air Bleeding of Brake System......................................................................................................................................................... 472 Front Brake Hose / Pipe Removal and Installation..................................................................................................................................... 474 Rear Brake Hose / Pipe Removal and Installation...................................................................................................................................... 474 Brake Hose and Pipe Inspection....................................................................................................................................................... 474 Master Cylinder Components........................................................................................................................................................... 475 Master Cylinder Reservoir Removal and Installation................................................................................................................................... 475 Master Cylinder Assembly Removal and Installation.................................................................................................................................... 476 Master Cylinder Assembly Disassembly and Assembly.................................................................................................................................... 477 Master Cylinder Assembly Inspection.................................................................................................................................................. 478 Brake Booster Components............................................................................................................................................................. 479 Booster Operation Inspection......................................................................................................................................................... 479 Brake Booster Removal and Installation............................................................................................................................................... 480 Brake Booster Inspection and Adjustment.............................................................................................................................................. 482 LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped)....................................................................................................................... 483 LSPV (Load Sensing Proportioning Valve) Removal and Installation..................................................................................................................... 483 LSPV (Load Sensing Proportioning Valve) Inspection and Adjustment.................................................................................................................... 484 Specifications........................................................................................................................................................................... 485 Tightening Torque Specifications..................................................................................................................................................... 485 Special Tools and Equipment.............................................................................................................................................................. 486 Recommended Service Material......................................................................................................................................................... 486 Special Tool......................................................................................................................................................................... 486 Front Brakes................................................................................................................................................................................. 487 Repair Instructions...................................................................................................................................................................... 487 Front Disc Brake Components.......................................................................................................................................................... 487 Front Disc Brake Pad On-Vehicle Inspection........................................................................................................................................... 488 Front Disc Brake Pad Removal and Installation........................................................................................................................................ 488 Front Disc Brake Pad Inspection...................................................................................................................................................... 489 Front Disc Brake Caliper Removal and Installation.................................................................................................................................... 489 Front Disc Brake Caliper Disassembly and Assembly.................................................................................................................................... 490 Front Disc Brake Caliper Inspection.................................................................................................................................................. 492 Front Brake Disc Removal and Installation............................................................................................................................................ 492 Front Brake Disc Inspection.......................................................................................................................................................... 493 Specifications........................................................................................................................................................................... 494 Tightening Torque Specifications..................................................................................................................................................... 494 Special Tools and Equipment.............................................................................................................................................................. 494 Recommended Service Material......................................................................................................................................................... 494 Special Tool......................................................................................................................................................................... 494 Rear Brakes.................................................................................................................................................................................. 495 Repair Instructions...................................................................................................................................................................... 495 Rear Drum Brake Components........................................................................................................................................................... 495 Rear Brake Drum Removal and Installation............................................................................................................................................. 495 Rear Brake Drum Inspection........................................................................................................................................................... 497 Rear Brake Shoe Removal and Installation............................................................................................................................................. 498 Rear Brake Shoe Inspection........................................................................................................................................................... 498 Wheel Cylinder Removal and Installation.............................................................................................................................................. 499 Wheel Cylinder Inspection............................................................................................................................................................ 500 Brake Back Plate Removal and Installation............................................................................................................................................ 500 Specifications........................................................................................................................................................................... 501 Tightening Torque Specifications..................................................................................................................................................... 501 Special Tools and Equipment.............................................................................................................................................................. 501 Recommended Service Material......................................................................................................................................................... 501 Parking Brake................................................................................................................................................................................ 502 General Description...................................................................................................................................................................... 502 Parking Brake Cable Construction..................................................................................................................................................... 502 Repair Instructions...................................................................................................................................................................... 503 Parking Brake Inspection and Adjustment.............................................................................................................................................. 503 Parking Brake Cable Removal and Installation......................................................................................................................................... 503 Specifications........................................................................................................................................................................... 504 Tightening Torque Specifications..................................................................................................................................................... 504 ABS.......................................................................................................................................................................................... 505 Precautions.............................................................................................................................................................................. 505 Precautions in Diagnosing Troubles................................................................................................................................................... 505 Precautions in On-Vehicle Service.................................................................................................................................................... 505 General Description...................................................................................................................................................................... 506 ABS Construction..................................................................................................................................................................... 506 ABS Hydraulic Unit / Control Module Assembly Description............................................................................................................................. 506 Schematic and Routing Diagram............................................................................................................................................................ 508 ABS Schematic........................................................................................................................................................................ 508 ABS Wiring Circuit Diagram........................................................................................................................................................... 509 Component Location....................................................................................................................................................................... 511 ABS Components Location.............................................................................................................................................................. 511 Front Wheel Speed Sensor Components Location......................................................................................................................................... 512 Rear Wheel Speed Sensor Components Location.......................................................................................................................................... 512 Diagnostic Information and Procedures.................................................................................................................................................... 513 ABS Check............................................................................................................................................................................ 513 ABS Warning Lamp Check............................................................................................................................................................... 515 EBD Warning Lamp (Brake Warning Lamp) Check.......................................................................................................................................... 515 DTC Check............................................................................................................................................................................ 516 DTC Table............................................................................................................................................................................ 517 DTC Clearance........................................................................................................................................................................ 518 Scan Tool Data....................................................................................................................................................................... 518 ABS Warning Lamp Does Not Come ON at Ignition Switch ON.............................................................................................................................. 519 ABS Warning Lamp Comes ON Steady..................................................................................................................................................... 520 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON.................................................................................................................... 522 Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground.................................................................................................. 523 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady................................................................................................................................ 524 Serial Data Link Circuit Check....................................................................................................................................................... 525 DTC C1015 (No. 15): G Sensor Circuit................................................................................................................................................. 527 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036 (No. 21, 22 / 25, 26 / 31, 32 / 35, 36): Wheel Speed Sensor Circuit or Sensor Ring..................................... 528 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056 (No. 41 / 45 / 51 / 55, No. 42 / 46 / 52 / 56): Inlet Solenoid Circuit, Outlet Solenoid Circuit................. 530 DTC C1057 (No. 57): Power Source Circuit............................................................................................................................................. 531 DTC C1061 (No. 61): ABS Pump Motor and/or Motor Relay Circuit........................................................................................................................ 533 DTC C1063 (No. 63): ABS Fail-Safe Relay Circuit...................................................................................................................................... 534 DTC C1071 (No. 71): ABS Control Module............................................................................................................................................... 535 Repair Instructions...................................................................................................................................................................... 536 ABS Hydraulic Unit Operation Check................................................................................................................................................... 536 ABS Hydraulic Unit / Control Module Assembly Components.............................................................................................................................. 538 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection................................................................................................................... 539 ABS Hydraulic Unit / Control Module Assembly Removal and Installation................................................................................................................ 539 Front Wheel Speed Sensor On-Vehicle Inspection....................................................................................................................................... 541 Front Wheel Speed Sensor Removal and Installation.................................................................................................................................... 541 Front Wheel Speed Sensor Inspection.................................................................................................................................................. 542 Rear Wheel Speed Sensor On-Vehicle Inspection........................................................................................................................................ 542 Rear Wheel Speed Sensor Removal and Installation..................................................................................................................................... 543 Rear Wheel Speed Sensor Inspection................................................................................................................................................... 544 Front Wheel Speed Sensor Ring On-Vehicle Inspection.................................................................................................................................. 544 Front Wheel Speed Sensor Ring Removal and Installation............................................................................................................................... 545 Rear Wheel Speed Sensor Ring On-Vehicle Inspection................................................................................................................................... 545 Rear Wheel Speed Sensor Ring Removal and Installation................................................................................................................................ 545 Specifications........................................................................................................................................................................... 546 Tightening Torque Specifications..................................................................................................................................................... 546 Special Tools and Equipment.............................................................................................................................................................. 546 Special Tool......................................................................................................................................................................... 546 Transmission / Transaxle......................................................................................................................................................................... 547 Precautions.................................................................................................................................................................................. 550 Precautions.............................................................................................................................................................................. 550 Precautions on Transmission / Transaxle.............................................................................................................................................. 550 Automatic Transmission/Transaxle............................................................................................................................................................. 551 Precautions.............................................................................................................................................................................. 551 Precautions in Diagnosing Trouble.................................................................................................................................................... 551 Precautions for Disassembly and Reassembly........................................................................................................................................... 551 General Description...................................................................................................................................................................... 553 A/T Description...................................................................................................................................................................... 553 Clutch / Brake / Planetary Gear Function of Automatic Transaxle...................................................................................................................... 556 Table of Component Operation......................................................................................................................................................... 557 Brake Interlock System Construction.................................................................................................................................................. 558 A/T Diagnosis General Description.................................................................................................................................................... 558 On-Board Diagnostic System Description............................................................................................................................................... 559 Schematic and Routing Diagram............................................................................................................................................................ 561 Transmission Control Module (TCM) Wiring Diagram..................................................................................................................................... 561 Automatic Gear Shift Diagram......................................................................................................................................................... 563 Component Location....................................................................................................................................................................... 565 Electronic Shift Control System Components Location.................................................................................................................................. 565 Diagnostic Information and Procedures.................................................................................................................................................... 567 A/T System Check..................................................................................................................................................................... 567 Visual Inspection.................................................................................................................................................................... 569 Malfunction Indicator Lamp (MIL) Check............................................................................................................................................... 570 “O/D OFF” Lamp Check................................................................................................................................................................. 570 DTC Table............................................................................................................................................................................ 570 DTC Check............................................................................................................................................................................ 573 DTC Clearance........................................................................................................................................................................ 574 Fail-Safe Table...................................................................................................................................................................... 575 Scan Tool Data....................................................................................................................................................................... 576 A/T Basic Check...................................................................................................................................................................... 579 Road Test............................................................................................................................................................................ 579 Manual Road Test..................................................................................................................................................................... 582 Engine Brake Test.................................................................................................................................................................... 582 Stall Test........................................................................................................................................................................... 583 Time Lag Test........................................................................................................................................................................ 584 Line Pressure Test................................................................................................................................................................... 585 “P” Range Test....................................................................................................................................................................... 586 A/T Symptom Diagnosis................................................................................................................................................................ 586 No Gear Shift to O/D................................................................................................................................................................. 594 No Lock-Up Occurs.................................................................................................................................................................... 595 DTC P0705 (No. 34): Transmission Range Sensor Circuit Malfunction.................................................................................................................... 596 DTC P0710 (No. 36 or 38): Transmission Fluid Temperature Sensor Circuit Malfunction.................................................................................................. 598 DTC P0715 (No. 14): Input / Turbine Speed Sensor Circuit Malfunction................................................................................................................. 600 DTC P0720 (No. 31): Output Speed Sensor / VSS Circuit Malfunction.................................................................................................................... 602 DTC P0725 (No. 35): Engine Speed Input Circuit Malfunction........................................................................................................................... 604 DTC P0741 (No. 29): TCC Circuit Performance or Stuck OFF............................................................................................................................. 606 DTC P0743 (No. 25 or 26): TCC Circuit Electrical..................................................................................................................................... 607 DTC P0748 (No. 41 or 42): Pressure Control Solenoid Electrical....................................................................................................................... 609 DTC P0751 / P0756 (No. 17 / No. 28): Shift Solenoid-A (No. 1) / -B (No. 2) Performance or Stuck OFF.................................................................................. 611 DTC P0753 / P0758 (No. 21 or 22 / No. 23 or 24): Shift Solenoid-A (No. 1) / -B (No. 2) Electrical.................................................................................... 612 DTC P0785 (No. 13): Timing Solenoid.................................................................................................................................................. 614 DTC P1700 (No. 32 or 33): Throttle Position Signal Circuit Malfunction............................................................................................................... 616 DTC P1702 (No. 52): Internal Malfunction of TCM...................................................................................................................................... 617 DTC P1705 (No. 51): Engine Coolant Temperature Signal Circuit Malfunction............................................................................................................ 618 DTC P1730 (No. 64): Engine Torque Signal Circuit Malfunction......................................................................................................................... 620 DTC P1895 (No. 27): Torque Reduction Signal Circuit Malfunction...................................................................................................................... 621 Inspection of TCM and Its Circuits................................................................................................................................................... 622 TCM Power and Ground Circuit Check................................................................................................................................................... 625 “O/D OFF” Lamp Circuit Check......................................................................................................................................................... 626 Brake Interlock System Inspection.................................................................................................................................................... 628 Repair Instructions...................................................................................................................................................................... 629 A/T Fluid Level Check................................................................................................................................................................ 629 A/T Fluid Change..................................................................................................................................................................... 630 Selector Lever Components............................................................................................................................................................ 631 Selector Lever Inspection............................................................................................................................................................ 631 Select Cable Components.............................................................................................................................................................. 632 Select Cable Removal and Installation................................................................................................................................................ 632 Selector Cable Adjustment............................................................................................................................................................ 632 Transmission Range Sensor (Shift Switch) Inspection and Adjustment................................................................................................................... 633 Output Shaft Speed Sensor / VSS Removal and Installation............................................................................................................................. 634 Output Shaft Speed Sensor / VSS Inspection........................................................................................................................................... 634 Input Shaft Speed Sensor Removal and Installation.................................................................................................................................... 635 Input Shaft Speed Sensor Inspection.................................................................................................................................................. 635 Transmission Fluid Temperature Sensor Removal and Installation....................................................................................................................... 635 Transmission Fluid Temperature Sensor Inspection..................................................................................................................................... 636 “O/D OFF” Switch Inspection.......................................................................................................................................................... 636 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Timing Solenoid Valve) Removal and Installation....................................................................... 637 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Timing Solenoid Valve) Inspection..................................................................................... 638 Pressure Control Solenoid Valve Removal and Installation............................................................................................................................. 640 Pressure Control Solenoid Valve Inspection........................................................................................................................................... 640 Transmission Control Module (TCM) Removal and Installation........................................................................................................................... 641 Learning Control Initialization...................................................................................................................................................... 642 Brief Learning....................................................................................................................................................................... 642 Differential Side Oil Seal Replacement............................................................................................................................................... 643 Shift Lock Solenoid Replacement...................................................................................................................................................... 644 Key Interlock Cable Removal and Installation......................................................................................................................................... 644 A/T Fluid Cooler Hoses Replacement................................................................................................................................................... 645 Automatic Transaxle Unit Components.................................................................................................................................................. 646 Automatic Transaxle Unit Dismounting and Remounting.................................................................................................................................. 647 Automatic Transaxle Assembly Components.............................................................................................................................................. 650 Automatic Transaxle Unit Disassembly................................................................................................................................................. 651 Oil Pump Components.................................................................................................................................................................. 663 Oil Pump Disassembly and Reassembly.................................................................................................................................................. 663 Oil Pump Inspection.................................................................................................................................................................. 664 Direct Clutch Components............................................................................................................................................................. 666 Direct Clutch Preliminary Check...................................................................................................................................................... 666 Direct Clutch Disassembly and Reassembly............................................................................................................................................. 667 Direct Clutch Inspection............................................................................................................................................................. 669 Forward and Reverse Clutch Assembly Components....................................................................................................................................... 670 Forward and Reverse Clutch Assembly Preliminary Check................................................................................................................................ 670 Forward and Reverse Clutch Assembly Disassembly and Reassembly....................................................................................................................... 671 Forward and Reverse Clutch Assembly Inspection....................................................................................................................................... 674 2nd Brake Piston Assembly Components................................................................................................................................................. 675 2nd Brake Piston Assembly Disassembly and Reassembly................................................................................................................................. 675 Transaxle Rear Cover and O/D and 2nd Coast Brake Piston Assembly Components.......................................................................................................... 676 Transaxle Rear Cover and O/D and 2nd Coast Brake Piston Assembly Disassembly and Reassembly.......................................................................................... 677 Transaxle Rear Cover and O/D and 2nd Coast Brake Piston Assembly Inspection.......................................................................................................... 678 Countershaft Assembly Components..................................................................................................................................................... 679 Countershaft Assembly Disassembly and Reassembly..................................................................................................................................... 679 Valve Body Assembly Components....................................................................................................................................................... 680 Valve Body Assembly Disassembly and Reassembly....................................................................................................................................... 681 Differential Assembly Components..................................................................................................................................................... 682 Differential Assembly Disassembly and Reassembly..................................................................................................................................... 683 Differential Assembly Inspection..................................................................................................................................................... 684 Torque Converter Housing Disassembly and Reassembly.................................................................................................................................. 685 Transaxle Case Disassembly and Reassembly............................................................................................................................................ 687 Automatic Transaxle Unit Inspection and Adjustment................................................................................................................................... 688 Automatic Transaxle Unit Assembly.................................................................................................................................................... 690 Specifications........................................................................................................................................................................... 707 Tightening Torque Specifications..................................................................................................................................................... 707 Special Tools and Equipment.............................................................................................................................................................. 709 Recommended Service Material......................................................................................................................................................... 709 Special Tool......................................................................................................................................................................... 709 Manual Transmission/Transaxle................................................................................................................................................................ 712 General Description...................................................................................................................................................................... 712 Manual Transaxle Construction........................................................................................................................................................ 712 Diagnostic Information and Procedures.................................................................................................................................................... 717 Manual Transaxle Symptom Diagnosis................................................................................................................................................... 717 Repair Instructions...................................................................................................................................................................... 717 Manual Transaxle Oil Change.......................................................................................................................................................... 717 Differential Side Oil Seal Replacement............................................................................................................................................... 718 Gear Shift Control Lever and Cable Components........................................................................................................................................ 719 Gear Shift Control Lever and Cable Removal and Installation.......................................................................................................................... 720 Vehicle Speed Sensor (VSS) Removal and Installation.................................................................................................................................. 720 Back Up Lamp Switch Removal and Installation......................................................................................................................................... 721 Back Up Lamp Switch Inspection....................................................................................................................................................... 721 Manual Transaxle Unit Components..................................................................................................................................................... 722 Manual Transaxle Unit Dismounting and Remounting..................................................................................................................................... 723 Gear Shift and Select Shaft Components............................................................................................................................................... 724 Gear Shift and Select Shaft Removal and Installation................................................................................................................................. 725 Gear Shift and Select Shaft Disassembly and Assembly................................................................................................................................. 726 Manual Transaxle Assembly Components................................................................................................................................................. 727 Fifth Gear Disassembly and Assembly.................................................................................................................................................. 728 Manual Transaxle Assembly Disassembly and Assembly................................................................................................................................... 730 Right Case Disassembly and Assembly.................................................................................................................................................. 736 Left Case Disassembly and Assembly................................................................................................................................................... 736 Input Shaft and Countershaft Components.............................................................................................................................................. 737 Input Shaft Disassembly and Assembly................................................................................................................................................. 738 Countershaft Disassembly and Assembly................................................................................................................................................ 740 Gear Shift Shaft Components.......................................................................................................................................................... 744 Gear Shift Shaft Disassembly and Assembly............................................................................................................................................ 744 Differential Components.............................................................................................................................................................. 745 Differential Disassembly and Assembly................................................................................................................................................ 746 Transfer Components.................................................................................................................................................................. 748 Transfer Assembly Disassembly and Assembly........................................................................................................................................... 749 Pinion Shaft Disassembly and Assembly................................................................................................................................................ 755 Output Shaft Disassembly and Assembly................................................................................................................................................ 757 Transfer Assembly Inspection......................................................................................................................................................... 758 Gear Tooth Surface Contact Inspection................................................................................................................................................ 758 Specifications........................................................................................................................................................................... 760 Tightening Torque Specifications..................................................................................................................................................... 760 Special Tools and Equipment.............................................................................................................................................................. 761 Recommended Service Material......................................................................................................................................................... 761 Special Tool......................................................................................................................................................................... 761 Clutch....................................................................................................................................................................................... 764 General Description...................................................................................................................................................................... 764 Clutch Construction.................................................................................................................................................................. 764 Diagnostic Information and Procedures.................................................................................................................................................... 765 Clutch System Symptom Diagnosis...................................................................................................................................................... 765 Repair Instructions...................................................................................................................................................................... 766 Clutch Pedal Inspection.............................................................................................................................................................. 766 Clutch Fluid Inspection.............................................................................................................................................................. 767 Clutch Fluid Pipe and Hose Components................................................................................................................................................ 767 Clutch Fluid Pipe and Hose Removal and Installation.................................................................................................................................. 768 Clutch Fluid Pipe and Hose Inspection................................................................................................................................................ 768 Clutch Master Cylinder Removal and Installation...................................................................................................................................... 769 Clutch Master Cylinder Components.................................................................................................................................................... 770 Clutch Master Cylinder Disassembly and Reassembly.................................................................................................................................... 770 Clutch Master Cylinder Inspection.................................................................................................................................................... 770 Clutch Operating Cylinder Removal and Installation................................................................................................................................... 771 Clutch Operating Cylinder Components................................................................................................................................................. 772 Clutch Operating Cylinder Disassembly and Reassembly................................................................................................................................. 772 Clutch Operating Cylinder Inspection................................................................................................................................................. 772 Clutch Cover, Clutch Disc, Flywheel and Clutch Release System Components............................................................................................................. 773 Clutch Cover, Clutch Disc and Flywheel Removal and Installation...................................................................................................................... 773 Clutch Cover, Clutch Disc and Flywheel Inspection.................................................................................................................................... 775 Clutch Release System Removal and Installation....................................................................................................................................... 775 Clutch Release System Inspection..................................................................................................................................................... 776 Specifications........................................................................................................................................................................... 777 Tightening Torque Specifications..................................................................................................................................................... 777 Special Tools and Equipment.............................................................................................................................................................. 777 Recommended Service Material......................................................................................................................................................... 777 Special Tool......................................................................................................................................................................... 778 Steering......................................................................................................................................................................................... 779 Precautions.................................................................................................................................................................................. 780 Precautions.............................................................................................................................................................................. 780 Precautions on Steering.............................................................................................................................................................. 780 Steering General Diagnosis................................................................................................................................................................... 781 Precautions.............................................................................................................................................................................. 781 Precautions for Steering, Suspension, Wheels and Tires Diagnosis..................................................................................................................... 781 Diagnostic Information and Procedures.................................................................................................................................................... 781 Steering Symptom Diagnosis........................................................................................................................................................... 781 Steering Wheel and Column.................................................................................................................................................................... 782 Precautions.............................................................................................................................................................................. 782 Service Precautions of Steering Wheel and Column..................................................................................................................................... 782 General Description...................................................................................................................................................................... 782 Steering Column Construction......................................................................................................................................................... 782 Steering Wheel and Driver Air Bag (Inflator) Module Construction..................................................................................................................... 782 Steering Wheel and Column Construction............................................................................................................................................... 783 Diagnostic Information and Procedures.................................................................................................................................................... 783 Inspection and Repair Required after Accident........................................................................................................................................ 783 Steering Wheel and Column Diagnosis.................................................................................................................................................. 783 Checking Steering Column Assembly for Accident Damage................................................................................................................................ 783 Repair Instructions...................................................................................................................................................................... 784 Steering Wheel Removal and Installation.............................................................................................................................................. 784 Contact Coil and Combination Switch Assembly Removal and Installation................................................................................................................ 786 Centering Contact Coil............................................................................................................................................................... 787 Contact Coil and Combination Switch Assembly Inspection.............................................................................................................................. 788 Steering Column Assembly Removal and Installation.................................................................................................................................... 788 Steering Column Assembly Inspection.................................................................................................................................................. 791 Steering Lock Assembly (Ignition Switch) Removal and Installation.................................................................................................................... 791 Steering Lower Shaft Removal and Installation........................................................................................................................................ 792 Specifications........................................................................................................................................................................... 793 Tightening Torque Specifications..................................................................................................................................................... 793 Special Tools and Equipment.............................................................................................................................................................. 793 Special Tool......................................................................................................................................................................... 793 Power Assisted Steering System............................................................................................................................................................... 794 Precautions.............................................................................................................................................................................. 794 P/S System Note...................................................................................................................................................................... 794 General Description...................................................................................................................................................................... 795 P/S System Description............................................................................................................................................................... 795 Diagnostic Information and Procedures.................................................................................................................................................... 796 P/S System Symptom Diagnosis......................................................................................................................................................... 796 Steering Wheel Play Check............................................................................................................................................................ 797 Steering Force Check................................................................................................................................................................. 797 Idle Up System Check................................................................................................................................................................. 797 Hydraulic Pressure in P/S Circuit Check.............................................................................................................................................. 798 Repair Instructions...................................................................................................................................................................... 799 P/S Fluid Level Check................................................................................................................................................................ 799 P/S Fluid Leakage Check.............................................................................................................................................................. 800 Air Bleeding Procedure............................................................................................................................................................... 801 P/S Pump Drive Belt On-Vehicle Inspection............................................................................................................................................ 801 P/S Pump Drive Belt Tension Adjustment............................................................................................................................................... 801 P/S Pump Drive Belt Removal and Installation......................................................................................................................................... 802 P/S Pump Drive Belt Inspection....................................................................................................................................................... 802 Tie-Rod End Boot On-Vehicle Inspection............................................................................................................................................... 802 Tie-Rod End Removal and Installation................................................................................................................................................. 802 Tie-Rod End Ball Joint Inspection.................................................................................................................................................... 803 P/S Gear Box Components.............................................................................................................................................................. 804 Steering Shaft Joint On-Vehicle Inspection........................................................................................................................................... 805 P/S Gear Box Removal and Installation................................................................................................................................................ 805 Steering Rack Boot On-Vehicle Inspection............................................................................................................................................. 807 Tie-Rod / Rack Boot Removal and Installation......................................................................................................................................... 807 P/S Pump Components.................................................................................................................................................................. 809 P/S Pump Removal and Installation.................................................................................................................................................... 810 P/S Pump Disassembly and Assembly.................................................................................................................................................... 810 P/S Pump Inspection.................................................................................................................................................................. 813 Specifications........................................................................................................................................................................... 814 P/S System Specification and Service Data............................................................................................................................................ 814 Tightening Torque Specifications..................................................................................................................................................... 815 Special Tools and Equipment.............................................................................................................................................................. 816 Recommended Service Material......................................................................................................................................................... 816 Special Tool......................................................................................................................................................................... 816 HVAC............................................................................................................................................................................................. 817 Precautions.................................................................................................................................................................................. 820 Precautions.............................................................................................................................................................................. 820 Precautions on HVAC.................................................................................................................................................................. 820 Heater and Ventilation....................................................................................................................................................................... 821 Precautions.............................................................................................................................................................................. 821 Precautions in Diagnosing Trouble.................................................................................................................................................... 821 General Description...................................................................................................................................................................... 821 Heater and Ventilation Construction.................................................................................................................................................. 821 On-Board Diagnostic System Description............................................................................................................................................... 822 Schematic and Routing Diagram............................................................................................................................................................ 823 Heater and Ventilation Wiring Circuit Diagram........................................................................................................................................ 823 Diagnostic Information and Procedures.................................................................................................................................................... 824 Heater and Ventilation Symptom Diagnosis............................................................................................................................................. 824 DTC Check............................................................................................................................................................................ 825 DTC Clearance........................................................................................................................................................................ 826 DTC Table............................................................................................................................................................................ 827 Fail-Safe Table...................................................................................................................................................................... 829 Scan Tool Data....................................................................................................................................................................... 829 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction..................................................................................... 830 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction........................................................................................ 830 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction....................................................................................................... 830 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction.......................................................................................................... 830 DTC B1520 (No.20): Temperature Selector and/ or its Circuit malfunction.............................................................................................................. 830 DTC B1521 (No.21): Blower Speed Selector and/ or Its Circuit......................................................................................................................... 830 DTC B1522 (No.22): Air Flow Selector and/or its Circuit Malfunction.................................................................................................................. 830 Inspection of HVAC Control Module and its Circuit.................................................................................................................................... 831 Repair Instructions...................................................................................................................................................................... 833 Blower Unit Components............................................................................................................................................................... 833 Blower Unit Removal and Installation................................................................................................................................................. 833 Blower Motor Removal and Installation................................................................................................................................................ 834 Blower Motor Inspection.............................................................................................................................................................. 834 Blower Motor Controller Removal and Installation..................................................................................................................................... 834 Blower Motor Controller Inspection................................................................................................................................................... 835 Blower Motor Relay Inspection........................................................................................................................................................ 835 Heater Unit Components............................................................................................................................................................... 836 Heater Unit Removal and Installation................................................................................................................................................. 836 HVAC Control Module Removal and Installation......................................................................................................................................... 837 Air Intake Control Actuator Removal and Installation................................................................................................................................. 837 Air Intake Control Actuator Inspection............................................................................................................................................... 838 Temperature Control Actuator Removal and Installation................................................................................................................................ 838 Temperature Control Actuator Inspection.............................................................................................................................................. 838 Air Flow Control Actuator Removal and Installation................................................................................................................................... 839 Air Flow Control Actuator Inspection................................................................................................................................................. 839 Actuator Linkage Inspection.......................................................................................................................................................... 840 Center Ventilation Louver Removal and Installation................................................................................................................................... 840 Side Ventilation Louver Removal and Installation..................................................................................................................................... 841 Special Tools and Equipment.............................................................................................................................................................. 841 Special Tool......................................................................................................................................................................... 841 Air Conditioning System...................................................................................................................................................................... 842 Manual Type.............................................................................................................................................................................. 842 Precautions.......................................................................................................................................................................... 842 A/C System Caution............................................................................................................................................................... 842 Precaution for Charging.......................................................................................................................................................... 842 Precaution in Diagnosing Trouble................................................................................................................................................. 843 Precautions on Servicing A/C System.............................................................................................................................................. 843 General Description.................................................................................................................................................................. 844 A/C Evaporator Inlet Air Temperature Sensor and A/C Evaporator Outlet Air Temperature Sensor Construction........................................................................ 844 Refrigerant Type Construction.................................................................................................................................................... 844 Sub-Cool System Description...................................................................................................................................................... 845 On-Board Diagnostic System Description........................................................................................................................................... 845 Schematic and Routing Diagram........................................................................................................................................................ 846 Major Components of A/C System................................................................................................................................................... 846 A/C System Wiring Diagram........................................................................................................................................................ 847 Diagnostic Information and Procedures................................................................................................................................................ 848 A/C System Symptom Diagnosis..................................................................................................................................................... 848 Abnormal Noise Symptom Diagnosis of A/C System................................................................................................................................... 850 DTC Check........................................................................................................................................................................ 851 DTC Clearance.................................................................................................................................................................... 851 DTC Table........................................................................................................................................................................ 851 Fail-Safe Table.................................................................................................................................................................. 851 Scan Tool Data................................................................................................................................................................... 852 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction................................................................................. 853 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction.................................................................................... 853 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction................................................................................................... 853 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction...................................................................................................... 853 DTC B1520 (No.20): Temperature Selector and/ or its Circuit malfunction.......................................................................................................... 853 DTC B1521 (No.21): Blower Speed Selector and/ or Its Circuit..................................................................................................................... 853 DTC B1522 (No.22): Air Flow Selector and/or its Circuit Malfunction.............................................................................................................. 853 Air Conditioning System Check.................................................................................................................................................... 853 Visual Inspection................................................................................................................................................................ 855 Inspection of HVAC Control Module and its Circuit................................................................................................................................ 855 A/C System Performance Inspection................................................................................................................................................ 857 A/C System Inspection at ECM..................................................................................................................................................... 861 Repair Instructions.................................................................................................................................................................. 863 Quick Checking of Refrigerant Charge............................................................................................................................................. 863 Operation Procedure for Refrigerant Charging..................................................................................................................................... 864 Heater and Cooling Unit Components............................................................................................................................................... 868 Heater and Cooling Unit Removal and Installation................................................................................................................................. 869 Condenser Assembly Removal and Installation...................................................................................................................................... 869 Condenser Assembly Inspection.................................................................................................................................................... 870 Desiccant Removal and Installation............................................................................................................................................... 870 Condenser Cooling Fan Removal and Installation................................................................................................................................... 870 Condenser Cooling Fan Inspection................................................................................................................................................. 871 A/C Evaporator Removal and Installation.......................................................................................................................................... 871 A/C Evaporator Inspection........................................................................................................................................................ 872 A/C Evaporator Inlet and Outlet Air Temperature Sensor Removal and Installation.................................................................................................. 872 A/C Evaporator Inlet and Outlet Air Temperature Sensors Inspection............................................................................................................... 873 Expansion Valve Removal and Installation......................................................................................................................................... 873 Expansion Valve Inspection....................................................................................................................................................... 873 A/C Refrigerant Pressure Switch Removal and Installation......................................................................................................................... 873 A/C Refrigerant Pressure Switch Inspection....................................................................................................................................... 874 Compressor Relay and Condenser Cooling Fan Relay Inspection...................................................................................................................... 874 Compressor Drive Belt Removal and Installation................................................................................................................................... 874 Compressor Drive Belt Inspection................................................................................................................................................. 874 Compressor Removal and Installation.............................................................................................................................................. 875 Compressor Inspection............................................................................................................................................................ 875 Magnet Clutch Components......................................................................................................................................................... 876 Magnet Clutch Removal and Installation........................................................................................................................................... 877 Specifications....................................................................................................................................................................... 879 Tightening Torque Specifications................................................................................................................................................. 879 Special Tools and Equipment.......................................................................................................................................................... 879 Recommended Service Material..................................................................................................................................................... 879 Special Tool..................................................................................................................................................................... 879 Automatic Type........................................................................................................................................................................... 880 Precautions.......................................................................................................................................................................... 880 Air Bag Warning.................................................................................................................................................................. 880 A/C System Caution............................................................................................................................................................... 880 Precaution for Charging.......................................................................................................................................................... 880 Precautions in Diagnosing Trouble................................................................................................................................................ 880 Precautions on Servicing A/C System.............................................................................................................................................. 880 General Description.................................................................................................................................................................. 880 A/C System Introduction.......................................................................................................................................................... 880 Refrigerant Type Construction.................................................................................................................................................... 882 Sub-Cool System Description...................................................................................................................................................... 882 On-Board Diagnostic System Description........................................................................................................................................... 882 Schematic and Routing Diagram........................................................................................................................................................ 882 Major Components of A/C System................................................................................................................................................... 882 A/C System Wiring Diagram........................................................................................................................................................ 883 Diagnostic Information and Procedures................................................................................................................................................ 884 A/C System Symptom Diagnosis..................................................................................................................................................... 884 Abnormal Noise Symptom Diagnosis of A/C System................................................................................................................................... 886 DTC Check........................................................................................................................................................................ 886 DTC Clearance.................................................................................................................................................................... 888 DTC Table........................................................................................................................................................................ 889 Fail-Safe Table.................................................................................................................................................................. 891 Scan Tool Data................................................................................................................................................................... 891 Air Conditioning System Check.................................................................................................................................................... 893 Visual Inspection................................................................................................................................................................ 895 DTC B1501 (No.01): Outside Air Temperature Sensor and/or its Circuit Malfunction................................................................................................. 895 DTC B1502 (No.02): Inside Air Temperature Sensor and/or its Circuit Malfunction.................................................................................................. 896 DTC B1503 (No.03): A/C Evaporator Air Temperature Sensor and/or its Circuit Malfunction.......................................................................................... 897 DTC B1504 (No.04): Sunload Sensor and/or its Circuit Malfunction................................................................................................................. 898 DTC B1510 (No.10): Engine Coolant Temperature (ECT) Sensor and/or its Circuit Malfunction........................................................................................ 899 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction................................................................................. 901 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction.................................................................................... 902 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction................................................................................................... 903 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction...................................................................................................... 906 DTC B1520 (No.20): Temperature Selector and/ or its Circuit malfunction.......................................................................................................... 908 DTC B1521 (No.21): Blower Speed Selector and/ or Its Circuit..................................................................................................................... 908 DTC B1522 (No.22): Air Flow Selector and/or its Circuit Malfunction.............................................................................................................. 908 Inspection of HVAC Control Module and its Circuit................................................................................................................................ 908 A/C System Performance Inspection................................................................................................................................................ 911 A/C System Inspection at ECM..................................................................................................................................................... 911 Repair Instructions.................................................................................................................................................................. 913 Quick Checking of Refrigerant Charge............................................................................................................................................. 913 Operation Procedure for Refrigerant Charging..................................................................................................................................... 913 Heater and Cooling Unit Components............................................................................................................................................... 913 Heater and Cooling Unit Removal and Installation................................................................................................................................. 913 Sunload Sensor Removal and Installation.......................................................................................................................................... 913 Sunload Sensor Inspection........................................................................................................................................................ 914 Outside Air Temperature Sensor Removal and Installation.......................................................................................................................... 914 Outside Air Temperature Sensor Inspection........................................................................................................................................ 914 Inside Air Temperature Sensor Removal and Installation........................................................................................................................... 914 Inside Air Temperature Sensor Inspection......................................................................................................................................... 915 Condenser Assembly Removal and Installation...................................................................................................................................... 915 Condenser Assembly Inspection.................................................................................................................................................... 915 Desiccant Removal and Installation............................................................................................................................................... 915 Condenser Cooling Fan Removal and Installation................................................................................................................................... 915 Condenser Cooling Fan Inspection................................................................................................................................................. 915 A/C Evaporator Removal and Installation.......................................................................................................................................... 915 A/C Evaporator Inspection........................................................................................................................................................ 915 A/C Evaporator Outlet Air Temperature Sensor Removal and Installation............................................................................................................ 915 A/C Evaporator Outlet Air Temperature Sensor Inspection.......................................................................................................................... 915 Expansion Valve Removal and Installation......................................................................................................................................... 916 Expansion Valve Inspection....................................................................................................................................................... 916 A/C Refrigerant Pressure Switch Removal and Installation......................................................................................................................... 916 A/C Refrigerant Pressure Switch Inspection....................................................................................................................................... 916 Compressor Relay and Condenser Cooling Fan Relay Inspection...................................................................................................................... 916 Compressor Drive Belt Removal and Installation................................................................................................................................... 916 Compressor Drive Belt Inspection................................................................................................................................................. 916 Compressor Removal and Installation.............................................................................................................................................. 916 Compressor Inspection............................................................................................................................................................ 916 Magnet Clutch Components......................................................................................................................................................... 916 Magnet Clutch Removal and Installation........................................................................................................................................... 916 Special Tools and Equipment.......................................................................................................................................................... 916 Special Tool..................................................................................................................................................................... 916 Restraint........................................................................................................................................................................................ 917 Precautions.................................................................................................................................................................................. 919 Precautions.............................................................................................................................................................................. 919 Precautions on Restraint............................................................................................................................................................. 919 Seat Belts................................................................................................................................................................................... 920 Precautions.............................................................................................................................................................................. 920 Precautions on Service and Diagnosis of Seat Belt.................................................................................................................................... 920 General Description...................................................................................................................................................................... 921 Seat Belt Construction............................................................................................................................................................... 921 Restraint System Specification....................................................................................................................................................... 922 Diagnostic Information and Procedures.................................................................................................................................................... 922 Inspection and Repair Required after Accident........................................................................................................................................ 922 Repair Instructions...................................................................................................................................................................... 923 Front Seat Belt Components........................................................................................................................................................... 923 Front Seat Belt Removal and Installation............................................................................................................................................. 924 Front Seat Belt Inspection........................................................................................................................................................... 924 Rear Seat Belt Removal and Installation.............................................................................................................................................. 926 Rear Seat Belt Inspection............................................................................................................................................................ 927 Specifications........................................................................................................................................................................... 927 Tightening Torque Specifications..................................................................................................................................................... 927 Air Bag System............................................................................................................................................................................... 928 Precautions.............................................................................................................................................................................. 928 Precautions on Service and Diagnosis of Air Bag System............................................................................................................................... 928 Precautions on Handling and Storage of Air Bag Components............................................................................................................................ 929 Precautions on Disposal of Air Bag and Seat Belt Pretensioner........................................................................................................................ 932 General Description...................................................................................................................................................................... 932 Air Bag System Construction.......................................................................................................................................................... 932 Schematic and Routing Diagram............................................................................................................................................................ 934 Air Bag System Wiring Diagram........................................................................................................................................................ 934 Component Location....................................................................................................................................................................... 936 Air Bag System Components, Wiring and Connectors Location............................................................................................................................ 936 Diagnostic Information and Procedures.................................................................................................................................................... 937 Repairs and Inspections Required after an Accident................................................................................................................................... 937 Inspection of Intermittents and Poor Connections..................................................................................................................................... 938 Air Bag Diagnostic System Check...................................................................................................................................................... 939 Air Bag Diagnostic System Check Flow................................................................................................................................................. 940 DTCs Description..................................................................................................................................................................... 941 DTC Table............................................................................................................................................................................ 941 DTC Check............................................................................................................................................................................ 944 DTC Clearance........................................................................................................................................................................ 945 Scan Tool Data....................................................................................................................................................................... 946 Scan Tool Data Definition............................................................................................................................................................ 946 “AIR BAG” Warning Lamp Comes ON Steady............................................................................................................................................... 946 “AIR BAG” Warning Lamp Does Not Come ON.............................................................................................................................................. 948 “AIR BAG” Warning Lamp Flashes....................................................................................................................................................... 951 “AIR BAG” Warning Lamp Cannot Indicate Flashing...................................................................................................................................... 952 SDM Cannot Communicate through the Serial Data Circuit............................................................................................................................... 954 DTC B1015: Passenger Air Bag Initiator Circuit Resistance High....................................................................................................................... 956 DTC B1016: Passenger Air Bag Initiator Circuit Resistance Low........................................................................................................................ 959 DTC B1018: Passenger Air Bag Initiator Circuit Short to Ground....................................................................................................................... 962 DTC B1019: Passenger Air Bag Initiator Circuit Short to Power Circuit................................................................................................................ 964 DTC B1021: Driver Air Bag Initiator Circuit Resistance High.......................................................................................................................... 967 DTC B1022: Driver Air Bag Initiator Circuit Resistance Low........................................................................................................................... 970 DTC B1024: Driver Air Bag Initiator Circuit Short to Ground.......................................................................................................................... 973 DTC B1025: Driver Air Bag Initiator Circuit Short to Power Circuit................................................................................................................... 976 DTC B1031: Power Source Voltage High................................................................................................................................................. 979 DTC B1032: Power Source Voltage Low.................................................................................................................................................. 981 DTC B1041 / B1045: Driver Pretensioner Initiator Circuit Resistance High............................................................................................................. 983 DTC B1042 / B1046: Driver / Passenger Pretensioner Initiator Circuit Resistance Low.................................................................................................. 986 DTC B1043 / B1047: Driver / Passenger Pretensioner Initiator Circuit Short to Ground................................................................................................. 989 DTC B1044 / B1048: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit.......................................................................................... 992 DTC B1051: Frontal Crash Detected (System Activation Command Outputted).............................................................................................................. 995 DTC B1056 / B1057: Sideward Crash (Driver / Passenger Side) Detected (Side Air Bag System Activation Command Outputted).............................................................. 995 DTC B1058: Frontal Crash Detected (Pretensioner Activation Command Outputted)........................................................................................................ 996 DTC B1061: “AIR BAG” Warning Lamp Circuit Failure.................................................................................................................................... 997 DTC B1063 / B1065: Side Sensor (Driver / Passenger Side) Circuit Short to Ground..................................................................................................... 998 DTC B1064 / B1066: Side Sensor (Driver / Passenger Side) Circuit Short to Power Circuit or Open......................................................................................1000 DTC B1071: Internal SDM Fault........................................................................................................................................................1003 DTC B1072 / B1074: Internal Side Sensor (Driver / Passenger Side) Fault..............................................................................................................1003 DTC B1073 / B1075 Side Sensor (Driver / Passenger Side) Correspondence Abnormality...................................................................................................1003 DTC B1081 / B1085: Side Air Bag (Driver / Passenger Side) Initiator Circuit Resistance High..........................................................................................1008 DTC B1082 / B1086 Side Air Bag (Driver / Passenger Side) Initiator Circuit Resistance Low............................................................................................1012 DTC B1083 / B1087 Side Air Bag (Driver / Passenger Side) Initiator Circuit Short to Ground...........................................................................................1016 DTC B1084 / B1088: Side Air Bag (Driver / Passenger Side) Initiator Circuit Short to Power Circuit...................................................................................1020 Repair Instructions......................................................................................................................................................................1023 Disabling Air Bag System.............................................................................................................................................................1023 Enabling Air Bag System..............................................................................................................................................................1024 SDM Removal and Installation.........................................................................................................................................................1025 SDM Inspection.......................................................................................................................................................................1026 Side Sensor Removal and Installation.................................................................................................................................................1027 Side Sensor Inspection...............................................................................................................................................................1028 Driver Air Bag (Inflator) Module Removal and Installation............................................................................................................................1028 Driver Air Bag (Inflator) Module Inspection..........................................................................................................................................1029 Passenger Air Bag (Inflator) Module Removal and Installation.........................................................................................................................1030 Passenger Air Bag (Inflator) Module Inspection.......................................................................................................................................1031 Side Air Bag (Inflator) Module Removal and Installation..............................................................................................................................1032 Side Air Bag (Inflator) Inspection...................................................................................................................................................1032 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal........................................................................................................................1033 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.....................................................................................................1042 Specifications...........................................................................................................................................................................1043 Tightening Torque Specifications.....................................................................................................................................................1043 Special Tools and Equipment..............................................................................................................................................................1043 Use of Special Tools.................................................................................................................................................................1043 Special Tool.........................................................................................................................................................................1045 Body, Cab and Accessories........................................................................................................................................................................1047 Precautions..................................................................................................................................................................................1052 Precautions..............................................................................................................................................................................1052 Precautions on Body, Cab and Accessories.............................................................................................................................................1052 Precautions for Body Service.........................................................................................................................................................1052 Fastener Caution for Body Service....................................................................................................................................................1052 Wiring Systems...............................................................................................................................................................................1053 Precautions..............................................................................................................................................................................1053 Cautions in Body Electrical System Servicing.........................................................................................................................................1053 Precautions for Wiring System........................................................................................................................................................1053 General Description......................................................................................................................................................................1054 Applicable model.....................................................................................................................................................................1054 Abbreviations........................................................................................................................................................................1054 Wire / Connector Color Symbols.......................................................................................................................................................1055 Symbols and Marks....................................................................................................................................................................1055 How to Read Connector Layout Diagram.................................................................................................................................................1057 How to Read Connector Codes and Terminal Nos.........................................................................................................................................1058 How to Read Ground Point.............................................................................................................................................................1060 How to Read Power Supply Diagram.....................................................................................................................................................1061 How to Read System Circuit Diagram...................................................................................................................................................1061 Connector Layout Diagram.................................................................................................................................................................1062 Connector Layout Diagram.............................................................................................................................................................1062 Engine Compartment for Connector Layout Diagram......................................................................................................................................1063 Instrument Panel for Connector Layout Diagram........................................................................................................................................1068 Door, Roof for Connector Layout Diagram..............................................................................................................................................1074 Floor for Connector Layout Diagram...................................................................................................................................................1076 Rear for Connector Layout Diagram....................................................................................................................................................1084 Ground Point.............................................................................................................................................................................1086 Ground (earth) Point.................................................................................................................................................................1086 Power Supply Diagram.....................................................................................................................................................................1088 Power Supply Diagram.................................................................................................................................................................1088 Power Supply Diagram (5 Door Type 1 - 3, 4 Door Type 1 - 2)..........................................................................................................................1089 Power Supply Diagram (5 Door Type 4, 4 Door Type 3)..................................................................................................................................1090 Fuses and the Protected Parts........................................................................................................................................................1091 Fuses in Main Fuse Box...............................................................................................................................................................1091 Individual Circuit Fuse Box, Supplementary Fuse Box (No. 1), Supplementary Fuse Box (No. 2)..........................................................................................1092 System Circuit Diagram...................................................................................................................................................................1094 System Circuit Diagram...............................................................................................................................................................1094 A-1 Cranking System Circuit Diagram..................................................................................................................................................1095 A-2 Charging System Circuit Diagram..................................................................................................................................................1096 A-3 Ignition System Circuit Diagram..................................................................................................................................................1097 A-4 Cooling System Circuit Diagram...................................................................................................................................................1098 A-5 Engine and A/C Control System Circuit Diagram....................................................................................................................................1099 A-6 4 A/T Control System Circuit Diagram.............................................................................................................................................1103 A-7 Immobilizer Control System Circuit Diagram.......................................................................................................................................1105 B-1 Windshield Wiper and Washer Circuit Diagram......................................................................................................................................1106 B-2 Rear Wiper and Washer Circuit Diagram (Instrument Panel Switch Type).............................................................................................................1107 B-2 Rear Wiper and Washer Circuit Diagram (Column Lever Switch Type).................................................................................................................1108 B-3 Rear Defogger Circuit Diagram (5 Door Type 1)....................................................................................................................................1109 B-3 Rear Defogger Circuit Diagram (5 Door Type 2 - 4, 4 Door)........................................................................................................................1110 B-4 Power Window Circuit Diagram.....................................................................................................................................................1111 B-5 Power Door Lock Circuit Diagram..................................................................................................................................................1113 B-6 Power Mirror Circuit Diagram.....................................................................................................................................................1115 B-7 Horn Circuit Diagram.............................................................................................................................................................1116 B-8 Seat Heater Circuit Diagram......................................................................................................................................................1117 C-1 Combination Meter Circuit Diagram (Meter) <5 Door Type 1 - 3, 4 Door Type 1 - 2>.................................................................................................1118 C-1 Combination Meter Circuit Diagram (Meter) <5 Door Type 4, 4 Door Type 3>.........................................................................................................1119 C-2 Combination Meter Circuit Diagram (Indicator) <5 Door Type 1 - 3, 4 Door Type 1 - 2>.............................................................................................1120 C-2 Combination Meter Circuit Diagram (Indicator) <5 Door Type 4, 4 Door Type 3>.....................................................................................................1121 C-3 Combination Meter Circuit Diagram (Warning Light) <5 Door Type 1 - 3, 4 Door Type 1 - 2>.........................................................................................1122 C-3 Combination Meter Circuit Diagram (Warning Light) <5 Door Type 4, 4 Door Type 3>.................................................................................................1124 D-1 Headlight System Circuit Diagram.................................................................................................................................................1126 D-2 Position, Tail and Licence Plate Light Circuit Diagram...........................................................................................................................1127 D-3 Fog Light Circuit Diagram........................................................................................................................................................1128 D-4 Illumination Light Circuit Diagram...............................................................................................................................................1129 D-5 Interior Light Circuit Diagram...................................................................................................................................................1130 D-6 Turn Signal and Hazard Warning Light Circuit Diagram.............................................................................................................................1131 D-7 Brake Light Circuit Diagram......................................................................................................................................................1132 D-8 Back-Up Light Circuit Diagram....................................................................................................................................................1133 D-9 Headlight Beam Leveling System Circuit Diagram...................................................................................................................................1134 D-10 Rear fog light Circuit Diagram <5 Door Type 1 - 3, 4 Door Type 1 - 2>...........................................................................................................1135 D-10 Rear fog light Circuit Diagram <5 Door Type 4, 4 Door Type 3>...................................................................................................................1136 E-1 Heater and Air Conditioner Circuit Diagram.......................................................................................................................................1137 E-2 Auto A/C System Circuit Diagram..................................................................................................................................................1138 F-1 Air-Bag Control System Circuit Diagram...........................................................................................................................................1140 F-2 Anti-Lock Brake System Circuit Diagram...........................................................................................................................................1142 G-1 Radio / Cigar Lighter Circuit Diagram (5 Door Type 1)............................................................................................................................1144 G-1 Radio / Cigar Lighter Circuit Diagram (5 Door Type 2 - 4, 4 Door)................................................................................................................1145 G-2 Clock Circuit Diagram............................................................................................................................................................1147 List of Connector........................................................................................................................................................................1148 List of Connector....................................................................................................................................................................1148 C Connector..........................................................................................................................................................................1148 E Connector..........................................................................................................................................................................1149 G Connector..........................................................................................................................................................................1150 J Connector..........................................................................................................................................................................1152 K Connector..........................................................................................................................................................................1153 L Connector..........................................................................................................................................................................1153 M Connector..........................................................................................................................................................................1155 O Connector (for 5 Door).............................................................................................................................................................1155 Lighting Systems.............................................................................................................................................................................1156 Component Location.......................................................................................................................................................................1156 Headlights, Turn Signal and Hazard Warning, Front and Rear Fog Light (If Equipped) System Location...................................................................................1156 Interior Light System Location.......................................................................................................................................................1157 Diagnostic Information and Procedures....................................................................................................................................................1157 Headlight Symptom Diagnosis..........................................................................................................................................................1157 Headlights with Leveling System (If Equipped) Symptom Diagnosis......................................................................................................................1158 Turn Signal and Hazard Warning Light Symptom Diagnosis...............................................................................................................................1158 Clearance, Tail and License Plate Light Symptom Diagnosis............................................................................................................................1158 Back-Up Light Symptom Diagnosis......................................................................................................................................................1159 Stop (Brake) Lamp Symptom Diagnosis..................................................................................................................................................1159 Front Fog Light (If Equipped) Symptom Diagnosis......................................................................................................................................1159 Rear Fog Light (If Equipped) Symptom Diagnosis.......................................................................................................................................1159 Interior Light Symptom Diagnosis.....................................................................................................................................................1160 Repair Instructions......................................................................................................................................................................1160 Headlight Housing Removal and Installation...........................................................................................................................................1160 Headlight Bulb Replacement...........................................................................................................................................................1161 Headlight Aiming Adjustment with Screen..............................................................................................................................................1161 Headlight Switch (in Lighting Switch) Removal and Installation.......................................................................................................................1162 Headlight Switch (in Lighting Switch) Inspection.....................................................................................................................................1163 Headlight Leveling Switch (If Equipped) Inspection...................................................................................................................................1163 Headlight Diode Removal and Installation.............................................................................................................................................1163 Headlight Diode Inspection...........................................................................................................................................................1164 Headlight, Clearance Light, Front / Rear Fog Light Relays Inspection.................................................................................................................1164 Hazard Switch Inspection.............................................................................................................................................................1164 Stop (Brake) Lamp Switch Inspection..................................................................................................................................................1164 Turn Signal Light Switch (in Lighting Switch) Removal and Installation...............................................................................................................1165 Turn Signal Light Switch (in Lighting Switch) Inspection.............................................................................................................................1165 Turn Signal and Hazard Relay Inspection..............................................................................................................................................1166 License Lamp Assembly (for Wagon Model) Removal and Installation.....................................................................................................................1166 Front Fog Light Assembly Removal and Installation....................................................................................................................................1166 Fog Light Bulb Replacement...........................................................................................................................................................1167 Front Fog Light Switch Inspection....................................................................................................................................................1167 Rear Fog Light Switch Inspection.....................................................................................................................................................1167 Instrumentation / Driver Info. / Horn........................................................................................................................................................1168 Schematic and Routing Diagram............................................................................................................................................................1168 Combination Meter Circuit Diagram....................................................................................................................................................1168 Component Location.......................................................................................................................................................................1170 Audio System Component Location......................................................................................................................................................1170 Diagnostic Information and Procedures....................................................................................................................................................1171 Speedometer and VSS Symptom Diagnosis................................................................................................................................................1171 Fuel Meter Symptom Diagnosis.........................................................................................................................................................1171 Low Fuel Warning Light Symptom Diagnosis.............................................................................................................................................1171 Oil Pressure Warning Light Symptom Diagnosis.........................................................................................................................................1171 Brake and Parking Brake Warning Light Symptom Diagnosis..............................................................................................................................1172 Seat Belt Warning Light (If Equipped) Symptom Diagnosis..............................................................................................................................1172 Ignition Key Reminder and Light Reminder Warning Buzzer Symptom Diagnosis............................................................................................................1172 A/T Shift Position Indicator (A/T Vehicle Only) Symptom Diagnosis....................................................................................................................1172 O/D OFF Indicator Lamp (A/T Vehicle Only) Symptom Diagnosis..........................................................................................................................1173 Cigarette Lighter (If Equipped) Symptom Diagnosis....................................................................................................................................1173 Horn Symptom Diagnosis...............................................................................................................................................................1173 Information Display (If Equipped) Symptom Diagnosis..................................................................................................................................1174 Audio System (If Equipped) Symptom Diagnosis.........................................................................................................................................1175 Remote Audio Control Switch (If Equipped) Symptom Diagnosis..........................................................................................................................1176 Repair Instructions......................................................................................................................................................................1177 Ignition Switch Removal and Installation.............................................................................................................................................1177 Ignition Switch Inspection...........................................................................................................................................................1177 Combination Meter Removal and Installation...........................................................................................................................................1178 Fuel Level Sensor Removal and Installation...........................................................................................................................................1178 Fuel Level Sensor Inspection.........................................................................................................................................................1178 Oil Pressure Switch Removal and Installation.........................................................................................................................................1179 Oil Pressure Switch On-Vehicle Inspection............................................................................................................................................1179 VSS Removal and Installation.........................................................................................................................................................1179 VSS Inspection.......................................................................................................................................................................1179 Engine Coolant Temperature (ECT) Sensor Inspection...................................................................................................................................1179 Brake Fluid Level Switch Inspection..................................................................................................................................................1179 Parking Brake Switch Inspection......................................................................................................................................................1180 Door Switch (Front / Rear Door) Inspection...........................................................................................................................................1180 Rearend Door Switch (for Wagon Model) Inspection.....................................................................................................................................1180 Trunk Lid Switch Inspection..........................................................................................................................................................1180 Outside Air Temperature Sensor (If Equipped with Information Display) Removal and Installation.......................................................................................1180 Outside Air Temperature Sensor (If Equipped with Information Display) Inspection.....................................................................................................1181 Instrument Panel Removal and Installation............................................................................................................................................1181 Information Display or Clock Removal and Installation................................................................................................................................1182 Radio Assembly Removal and Installation..............................................................................................................................................1182 Front Speaker Removal and Installation...............................................................................................................................................1183 Rear Speaker (for Sedan Model) Removal and Installation..............................................................................................................................1183 Rear Speaker (for Wagon Model) Removal and Installation..............................................................................................................................1183 Antenna Amplifier (for Sedan Model) Removal and Installation.........................................................................................................................1184 Antenna Amplifier (for Wagon Model) Removal and Installation.........................................................................................................................1184 Remote Audio Control Switch Inspection...............................................................................................................................................1184 Specifications...........................................................................................................................................................................1185 Tightening Torque Specifications.....................................................................................................................................................1185 Wipers / Washers.............................................................................................................................................................................1186 Diagnostic Information and Procedures....................................................................................................................................................1186 Front Wiper and Washer Symptom Diagnosis.............................................................................................................................................1186 Rear Wiper and Washer (If Equipped) Symptom Diagnosis................................................................................................................................1186 Repair Instructions......................................................................................................................................................................1187 Wipers and Washers Components........................................................................................................................................................1187 Washer Tank and Washer Pump Removal and Installation.................................................................................................................................1188 Washer Pump Inspection...............................................................................................................................................................1188 Windshield Wiper Motor Inspection....................................................................................................................................................1188 Rear Wiper Motor (If Equipped) Inspection............................................................................................................................................1189 Windshield Wiper and Washer Switch Removal and Installation..........................................................................................................................1189 Windshield Wiper and Washer Switch Inspection........................................................................................................................................1190 Rear Wiper and Washer Switch Removal and Installation................................................................................................................................1191 Rear Wiper and Washer Switch Inspection..............................................................................................................................................1192 Rear Wiper Intermittent Relay Removal and Installation...............................................................................................................................1192 Rear Wiper Intermittent Relay Inspection.............................................................................................................................................1192 Glass / Windows / Mirrors....................................................................................................................................................................1194 General Description......................................................................................................................................................................1194 Windshield Construction..............................................................................................................................................................1194 Component Location.......................................................................................................................................................................1195 Power Window Control System Location.................................................................................................................................................1195 Diagnostic Information and Procedures....................................................................................................................................................1196 Rear Window Defogger Symptom Diagnosis...............................................................................................................................................1196 Power Window Control System Symptom Diagnosis........................................................................................................................................1196 Power Door Mirror Control System (If Equipped) Symptom Diagnosis.....................................................................................................................1196 Door Mirror Heater (If Equipped) Symptom Diagnosis...................................................................................................................................1196 Repair Instructions......................................................................................................................................................................1197 Windshield Removal and Installation..................................................................................................................................................1197 Front Pillar Window Removal and Installation.........................................................................................................................................1200 Front Door Window Components.........................................................................................................................................................1201 Front Door Glass Removal and Installation............................................................................................................................................1201 Front Door Window Regulator Removal and Installation.................................................................................................................................1202 Front Door Window Regulator Inspection...............................................................................................................................................1203 Rear Door Window Components..........................................................................................................................................................1203 Rear Door Glass Removal and Installation.............................................................................................................................................1204 Rear Door Window Regulator Removal and Installation..................................................................................................................................1205 Rear Door Window Regulator Inspection................................................................................................................................................1206 Quarter Window (for Wagon Model) Removal and Installation............................................................................................................................1206 Rearend Door Window (for Wagon Model) Components.....................................................................................................................................1207 Rearend Door Glass (for Wagon Model) Removal and Installation........................................................................................................................1207 Back Window (for Sedan Model) Components.............................................................................................................................................1208 Back Window (for Sedan Model) Removal and Installation...............................................................................................................................1208 Rearend Door Window / Back Window Defogger Switch and Its Circuit Inspection.........................................................................................................1209 Rearend Door Window / Back Window Defogger Wire Inspection...........................................................................................................................1209 Rearend Door Window / Back Window Defogger Wire Repair...............................................................................................................................1211 Power Window Main Switch Inspection..................................................................................................................................................1211 Power Window Sub Switch Inspection...................................................................................................................................................1212 Door Mirror Components...............................................................................................................................................................1212 Door Mirror Removal and Installation.................................................................................................................................................1212 Power Door Mirror Switch Inspection..................................................................................................................................................1213 Power Door Mirror Actuator Inspection................................................................................................................................................1213 Door Mirror Heater Switch (If Equipped) Inspection...................................................................................................................................1214 Door Mirror Heater (If Equipped) Inspection..........................................................................................................................................1214 Specifications...........................................................................................................................................................................1215 Tightening Torque Specifications.....................................................................................................................................................1215 Special Tools and Equipment..............................................................................................................................................................1215 Recommended Service Material.........................................................................................................................................................1215 Security and Locks...........................................................................................................................................................................1216 General Description......................................................................................................................................................................1216 Key Coding Construction..............................................................................................................................................................1216 Component Location.......................................................................................................................................................................1216 Power Door Lock and Keyless Entry System (If Equipped) Component Location............................................................................................................1216 Diagnostic Information and Procedures....................................................................................................................................................1217 Power Door Lock System (If Equipped) Symptom Diagnosis...............................................................................................................................1217 Power Door Lock System Operation Inspection..........................................................................................................................................1218 Power Door Lock System Circuit Inspection............................................................................................................................................1218 Keyless Entry System (If Equipped) Symptom Diagnosis.................................................................................................................................1220 Keyless Entry System Operation Inspection............................................................................................................................................1220 Keyless Entry System Circuit Inspection..............................................................................................................................................1221 Repair Instructions......................................................................................................................................................................1222 Front Door Lock Assembly Components..................................................................................................................................................1222 Front Door Lock Assembly Removal and Installation....................................................................................................................................1223 Power Door Lock Switch (If Equipped) Inspection......................................................................................................................................1224 Door Key Cylinder Switch (Driver and Passenger Side) Inspection......................................................................................................................1224 Power Door Lock Actuator Inspection..................................................................................................................................................1225 Front Door Lock Assembly Inspection..................................................................................................................................................1226 Rear Door Lock Assembly Components...................................................................................................................................................1226 Rear Door Lock Assembly Removal and Installation.....................................................................................................................................1227 Rear Door Lock Assembly Inspection...................................................................................................................................................1227 Rearend Door Lock Assembly (for Wagon Model) Components..............................................................................................................................1228 Rearend Door Lock Assembly (for Wagon Model) Removal and Installation................................................................................................................1229 Rearend Door Lock Assembly (for Wagon Model) Inspection..............................................................................................................................1229 Trunk Lid Lock Assembly (for Sedan Model) Components.................................................................................................................................1230 Trunk Lid Lock Assembly (for Sedan Model) Removal and Installation...................................................................................................................1230 Trunk Lid Lock Assembly (for Sedan Model) Inspection.................................................................................................................................1231 Replacement of Transmitter Battery...................................................................................................................................................1231 Programming Transmitter Code.........................................................................................................................................................1231 Special Tools and Equipment..............................................................................................................................................................1232 Recommended Service Material.........................................................................................................................................................1232 Seats........................................................................................................................................................................................1233 Diagnostic Information and Procedures....................................................................................................................................................1233 Front Seat Heater (If Equipped) Symptom Diagnosis....................................................................................................................................1233 Repair Instructions......................................................................................................................................................................1234 Front Seat Components................................................................................................................................................................1234 Front Seat Removal and Installation..................................................................................................................................................1235 Rear Seat Components.................................................................................................................................................................1235 Rear Seat Removal and Installation...................................................................................................................................................1236 Seat Heater Switch (Driver and Passenger Side) Inspection............................................................................................................................1237 Seat Heater Wire Inspection..........................................................................................................................................................1237 Specifications...........................................................................................................................................................................1238 Tightening Torque Specifications.....................................................................................................................................................1238 Interior Trim................................................................................................................................................................................1239 Repair Instructions......................................................................................................................................................................1239 Floor Carpet Removal and Installation................................................................................................................................................1239 Head Lining Removal and Installation.................................................................................................................................................1239 Console Box Components...............................................................................................................................................................1241 Specifications...........................................................................................................................................................................1241 Tightening Torque Specifications.....................................................................................................................................................1241 Hood / Fenders / Doors.......................................................................................................................................................................1242 Repair Instructions......................................................................................................................................................................1242 Hood Removal and Installation........................................................................................................................................................1242 Hood Inspection and Adjustment.......................................................................................................................................................1242 Front Fender Components..............................................................................................................................................................1243 Front Fender Removal and Installation................................................................................................................................................1243 Front Door Assembly Components.......................................................................................................................................................1244 Front Door Assembly Removal and Installation.........................................................................................................................................1244 Rear Door Assembly Components........................................................................................................................................................1246 Rear Door Assembly Removal and Installation..........................................................................................................................................1246 Rearend Door Assembly (for Wagon Model) Components...................................................................................................................................1247 Rearend Door Assembly (for Wagon Model) Removal and Installation.....................................................................................................................1248 Trunk Lid (for Sedan Model) Components...............................................................................................................................................1249 Trunk Lid (for Sedan Model) Removal and Installation.................................................................................................................................1249 Specifications...........................................................................................................................................................................1251 Tightening Torque Specifications.....................................................................................................................................................1251 Special Tools and Equipment..............................................................................................................................................................1251 Recommended Service Material.........................................................................................................................................................1251 Body Structure...............................................................................................................................................................................1252 Repair Instructions......................................................................................................................................................................1252 Front Bumper and Rear Bumper Components..............................................................................................................................................1252 Front and Rear Bumper Side Garnish Removal and Installation..........................................................................................................................1254 Specifications...........................................................................................................................................................................1254 Body Dimensions......................................................................................................................................................................1254 Paint / Coatings.............................................................................................................................................................................1263 Sedan....................................................................................................................................................................................1263 General Description..................................................................................................................................................................1263 Anti-Corrosion Treatment Construction............................................................................................................................................1263 Plastic Parts Finishing..........................................................................................................................................................1263 Component Location...................................................................................................................................................................1264 Sealant Application Areas........................................................................................................................................................1264 Under Coating Application Areas..................................................................................................................................................1266 Anti-Corrosion Compound Application Area.........................................................................................................................................1268 Wagon....................................................................................................................................................................................1269 General Description..................................................................................................................................................................1269 Anti-Corrosion Treatment Construction............................................................................................................................................1269 Plastic Parts Finishing..........................................................................................................................................................1269 Component Location...................................................................................................................................................................1270 Sealant Application Areas........................................................................................................................................................1270 Under Coating Application Areas..................................................................................................................................................1276 Anti-Corrosion Compound Application Area.........................................................................................................................................1277 Exterior Trim................................................................................................................................................................................1278 Repair Instructions......................................................................................................................................................................1278 Roof Molding Components..............................................................................................................................................................1278 Splash Guard (If Equipped) Components................................................................................................................................................1279 Control Systems..................................................................................................................................................................................1281 Immobilizer Control System...................................................................................................................................................................1282 Precautions..............................................................................................................................................................................1282 Precautions in Diagnosing Troubles...................................................................................................................................................1282 Precautions in Handling Immobilizer Control System...................................................................................................................................1283 General Description......................................................................................................................................................................1284 Immobilizer Control System Introduction..............................................................................................................................................1284 On-Board Diagnostic System Description (Self- diagnosis Function)....................................................................................................................1285 Schematic and Routing Diagram............................................................................................................................................................1286 Immobilizer Control System Wiring Circuit Diagram....................................................................................................................................1286 Diagnostic Information and Procedures....................................................................................................................................................1287 Immobilizer Control System Check.....................................................................................................................................................1287 DTC Check............................................................................................................................................................................1289 DTC Table............................................................................................................................................................................1290 Immobilizer Indicator Lamp Does Not Light at Ignition Switch ON (Equipped with Immobilizer Indicator Lamp)...........................................................................1291 Immobilizer Indicator Lamp Remains ON after Engine Starts (Equipped with Immobilizer Indicator Lamp).................................................................................1292 DTC Is Not Output from Immobilizer Control Module....................................................................................................................................1293 DTC 11 / 32: Transponder Code Not Matched............................................................................................................................................1294 DTC 31: Transponder Code Not Registered..............................................................................................................................................1294 DTC 12: Fault in Immobilizer Control Module..........................................................................................................................................1294 DTC 13: No Transponder Code Transmitted or Coil Antenna Opened/Shorted...............................................................................................................1295 DTC 21 / 81 (P1623) / 84 (P1620): ECM/ Immobilizer Control Module (ECU) Code Not Matched.............................................................................................1296 DTC 82 (P1622): Fault in ECM.........................................................................................................................................................1296 DTC 22: Ignition Switch Circuit Open/Short...........................................................................................................................................1296 DTC 23 / 83 (P1621): No ECM/Immobilizer Control Module Code Transmitted or DLC Circuit Opened/ Shorted...............................................................................1297 Inspection of ECM, Immobilizer Control Module and Its Circuit........................................................................................................................1299 Repair Instructions......................................................................................................................................................................1300 Immobilizer Control Module Removal and Installation..................................................................................................................................1300 How to Register Ignition Key.........................................................................................................................................................1301 Procedure after Immobilizer Control Module Replacement...............................................................................................................................1301 Procedure after ECM Replacement......................................................................................................................................................1301 Special Tools and Equipment..............................................................................................................................................................1301 Special Tool.........................................................................................................................................................................1301 COPYRIGHT........................................................................................................................................................................................1302 BOOKCOVER_VOL1...................................................................................................................................................................................1303 BOOKCOVER_VOL2...................................................................................................................................................................................1304
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