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SUZUKI RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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“Suzuki RH416 Liana Supplementary Service Manual” provides extra instructions for model-specific maintenance, complementing the main manual for thorough care and optimal vehicle performance.
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SUZUKI RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 603
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI RH416 LIANA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcover.................................................................................................................................................. 1 99501_54G40_01E............................................................................................................................................ 2 IMPORTANT.............................................................................................................................................. 2 FOREWORD............................................................................................................................................... 4 TABLE OF CONTENTS...................................................................................................................................... 6 Precautions............................................................................................................................................ 8 Precautions........................................................................................................................................ 9 Precautions.................................................................................................................................... 9 General Precautions........................................................................................................................ 9 Precaution for CAN Communication System.................................................................................................... 11 General Information.................................................................................................................................... 12 General Information................................................................................................................................ 13 General Description............................................................................................................................ 13 Abbreviations.............................................................................................................................. 13 Symbols.................................................................................................................................... 14 Fasteners Information...................................................................................................................... 15 Maintenance and Lubrication........................................................................................................................ 17 Scheduled Maintenance.......................................................................................................................... 17 Normal Condition Schedule.................................................................................................................. 17 Maintenance Recommended under Severe Driving Conditions.................................................................................... 18 Repair Instructions............................................................................................................................ 19 Engine Oil and Filter Change............................................................................................................... 19 Air Cleaner Filter Inspection.............................................................................................................. 20 Air Cleaner Filter Replacement............................................................................................................. 20 Fuel Lines and Connections Inspection...................................................................................................... 20 Fuel Filter Replacement.................................................................................................................... 21 Brake Lever and Cable Inspection........................................................................................................... 21 Clutch Fluid Inspection.................................................................................................................... 21 HVAC Air Filter (If Equipped) Inspection................................................................................................... 21 HVAC Air Filter (If Equipped) Replacement.................................................................................................. 21 Specifications................................................................................................................................. 22 Tightening Torque Specifications........................................................................................................... 22 Special Tools and Equipment.................................................................................................................... 22 Recommended Fluids and Lubricants.......................................................................................................... 22 Special Tool............................................................................................................................... 22 Engine................................................................................................................................................. 24 Precautions........................................................................................................................................ 29 Precautions.................................................................................................................................... 29 Precautions for Engine..................................................................................................................... 29 Engine General Information and Diagnosis........................................................................................................... 30 Precautions.................................................................................................................................... 30 Precautions on Engine Service.............................................................................................................. 30 Precautions in Diagnosing Trouble.......................................................................................................... 30 General Description............................................................................................................................ 31 Statement on Cleanliness and Care.......................................................................................................... 31 Engine Diagnosis General Description....................................................................................................... 31 On-Board Diagnostic System Description..................................................................................................... 32 Engine and Emission Control System Description............................................................................................. 36 Air Intake System Description.............................................................................................................. 36 CAN Communication System Description....................................................................................................... 37 Electronic Control System Description...................................................................................................... 37 Engine and Emission Control Input / Output Table........................................................................................... 42 Schematic and Routing Diagram.................................................................................................................. 43 Engine and Emission Control System Diagram................................................................................................. 43 Component Location............................................................................................................................. 44 Electronic Control System Components Location.............................................................................................. 44 Diagnostic Information and Procedures.......................................................................................................... 45 Engine and Emission Control System Check................................................................................................... 45 Malfunction Indicator Lamp (MIL) Check..................................................................................................... 48 DTC Check.................................................................................................................................. 49 DTC Clearance.............................................................................................................................. 49 DTC Table.................................................................................................................................. 50 Fail-Safe Table............................................................................................................................ 55 Scan Tool Data............................................................................................................................. 56 Visual Inspection.......................................................................................................................... 60 Engine Basic Inspection.................................................................................................................... 61 Engine Symptom Diagnosis................................................................................................................... 64 Malfunction Indicator Lamp Does Not Come ON While Ignition Switch is Turned ON with Engine at Stop (But Engine Can be Started)............. 71 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................. 73 DTC P0010: Camshaft Position Actuator Circuit.............................................................................................. 74 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded.............................................. 76 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)....................................................................... 78 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)....................................................................... 80 DTC P0101: Mass Air Flow Circuit Range / Performance....................................................................................... 82 DTC P0102: Mass Air Flow Circuit Low Input................................................................................................. 85 DTC P0103: Mass Air Flow Circuit High Input................................................................................................ 87 DTC P0106: Manifold Absolute Pressure Circuit Range / Performance.......................................................................... 88 DTC P0107: Manifold Absolute Pressure Circuit Low Input.................................................................................... 90 DTC P0108: Manifold Absolute Pressure Circuit High Input................................................................................... 91 DTC P0111: Intake Air Temperature Sensor Circuit Range / Performance....................................................................... 93 DTC P0112: Intake Air Temperature Sensor Circuit Low....................................................................................... 96 DTC P0113: Intake Air Temperature Sensor Circuit High...................................................................................... 97 DTC P0116: Engine Coolant Temperature Circuit Range / Performance.......................................................................... 99 DTC P0117: Engine Coolant Temperature Circuit Low..........................................................................................102 DTC P0118: Engine Coolant Temperature Circuit High.........................................................................................103 DTC P0121: Throttle Position Sensor Circuit Range / Performance............................................................................105 DTC P0122: Throttle Position Sensor Circuit Low............................................................................................109 DTC P0123: Throttle Position Sensor Circuit High...........................................................................................111 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)..........................................................113 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)...............................................................................116 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)........................................................................117 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)..........................................................119 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)........................................................................122 DTC P0171 / P0172: Fuel System Too Lean / Rich.............................................................................................124 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected....126 DTC P0327 / P0328: Knock Sensor Circuit Low / High.........................................................................................128 DTC P0335: Crankshaft Position (CKP) Sensor Circuit........................................................................................130 DTC P0340: Camshaft Position (CMP) Sensor Circuit..........................................................................................132 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected...............................................135 DTC P0403: Exhaust Gas Recirculation Control Circuit.......................................................................................137 DTC P0420: Catalyst System Efficiency below Threshold......................................................................................139 DTC P0443: Evaporative Emission System Purge Control Valve Circuit.........................................................................141 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit....................................................................................143 DTC P0481: Fan 2 (Condenser Cooling Fan) Control Circuit...................................................................................146 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction..........................................................................................148 DTC P0505: Idle Air Control System.........................................................................................................150 DTC P0601 / P0602: Internal Control Module Memory Check Sum Error / Control Module Programming Error.......................................152 DTC P0616: Starter Relay Circuit Low.......................................................................................................153 DTC P0617: Starter Relay Circuit High......................................................................................................154 DTC P1510: ECM Back-Up Power Supply Malfunction............................................................................................155 DTC P1603: TCM Trouble Code Detected.......................................................................................................156 DTC P1674: CAN Communication (Bus Off Error)...............................................................................................157 DTC P1675: CAN Communication (Transmission Error for TCM)..................................................................................159 DTC P1676: CAN Communication (Reception Error for TCM).....................................................................................160 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction.........................................................................162 Inspection of ECM and Its Circuits.........................................................................................................163 ECM Power and Ground Circuit Check.........................................................................................................180 Fuel Injector Circuit Check................................................................................................................183 Fuel Pump and Its Circuit Check............................................................................................................185 Fuel Pressure Check........................................................................................................................187 Idle Air Control System Check..............................................................................................................189 A/C System Circuits Check..................................................................................................................191 Electric Load Signal Circuit Check.........................................................................................................194 Radiator Cooling Fan Low Speed Control System Check........................................................................................195 Radiator Cooling Fan High Speed Control System Check.......................................................................................197 Power Steering Pressure (PSP) Switch Signal Circuit Check..................................................................................199 Generator Control Signal Circuit Check.....................................................................................................200 Repair Instructions............................................................................................................................201 Idle Speed / Idle Air Control (IAC) Duty Inspection........................................................................................201 Special Tools and Equipment....................................................................................................................202 Special Tool...............................................................................................................................202 Aux. Emission Control Devices......................................................................................................................203 Diagnostic Information and Procedures..........................................................................................................203 EGR System Inspection (Using SUZUKI Scan Tool).............................................................................................203 Repair Instructions............................................................................................................................203 EVAP Canister Inspection...................................................................................................................203 EVAP Canister Purge Inspection.............................................................................................................204 EVAP Canister Purge Valve and Its Circuit Inspection.......................................................................................204 EVAP Canister Purge Valve Inspection.......................................................................................................205 Vacuum Passage Inspection..................................................................................................................206 Vacuum Hose Inspection.....................................................................................................................206 EGR Valve Removal and Installation.........................................................................................................206 EGR Valve Inspection.......................................................................................................................207 PCV Hose Inspection........................................................................................................................207 PCV Valve Inspection.......................................................................................................................207 Special Tools and Equipment....................................................................................................................208 Special Tool...............................................................................................................................208 Engine Electrical Devices..........................................................................................................................209 Repair Instructions............................................................................................................................209 Idle Air Control (IAC) Valve Operation Inspection..........................................................................................209 Idle Air Control (IAC) Valve Removal and Installation......................................................................................209 Idle Air Control (IAC) Valve Inspection....................................................................................................210 Engine Control Module (ECM) Removal and Installation.......................................................................................210 Manifold Absolute Pressure (MAP) Sensor Removal and Installation...........................................................................210 Manifold Absolute Pressure (MAP) Sensor Inspection.........................................................................................211 Throttle Position (TP) Sensor On-Vehicle Inspection........................................................................................212 Throttle Position (TP) Sensor Removal and Installation.....................................................................................212 Engine Coolant Temperature (ECT) Sensor Removal and Installation...........................................................................213 Engine Coolant Temperature (ECT) Sensor Inspection.........................................................................................213 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation..........................................................................213 Oxygen Sensor Heater Inspection............................................................................................................214 Camshaft Position (CMP) Sensor Removal and Installation....................................................................................214 Camshaft Position (CMP) Sensor Inspection..................................................................................................215 Crankshaft Position (CKP) Sensor Removal and Installation..................................................................................215 Crankshaft Position (CKP) Sensor Inspection................................................................................................216 Vehicle Speed Sensor (VSS) Inspection......................................................................................................216 Knock Sensor Removal and Installation......................................................................................................217 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection.....................................................................217 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation.......................................................218 Main Relay, Fuel Pump Relay, A/C Compressor Relay and A/C Condenser Fan Relay Inspection...................................................218 Radiator Fan Relay No.1, No.2 and No.3 Inspection..........................................................................................218 Specifications.................................................................................................................................219 Tightening Torque Specifications...........................................................................................................219 Special Tools and Equipment....................................................................................................................219 Special Tool...............................................................................................................................219 Engine Mechanical..................................................................................................................................220 General Description............................................................................................................................220 Engine Construction Description............................................................................................................220 Camshaft Position Control (VVT Variable Valve Timing) System Description...................................................................221 Diagnostic Information and Procedures..........................................................................................................224 Compression Check..........................................................................................................................224 Engine Vacuum Check........................................................................................................................225 Valve Lash (Clearance) Inspection..........................................................................................................226 Repair Instructions............................................................................................................................229 Air Intake System Components...............................................................................................................229 Air Cleaner Assembly Removal and Installation..............................................................................................229 Air Cleaner Filter Removal and Installation................................................................................................230 Air Cleaner Filter Inspection and Cleaning.................................................................................................230 Cylinder Head Cover Removal and Installation...............................................................................................230 Accelerator Cable Adjustment...............................................................................................................232 Throttle Body and Intake Manifold Components...............................................................................................233 Throttle Body On-Vehicle Inspection........................................................................................................234 Throttle Body Removal and Installation.....................................................................................................234 Throttle Body Cleaning.....................................................................................................................235 Intake Manifold Removal and Installation...................................................................................................235 Engine Mountings Components................................................................................................................236 Engine Assembly Removal and Installation...................................................................................................237 Timing Chain Cover Components..............................................................................................................241 Timing Chain Cover Removal and Installation................................................................................................242 Timing Chain Cover Inspection..............................................................................................................244 Oil Control Valve Removal and Installation.................................................................................................245 Oil Control Valve Inspection...............................................................................................................245 Timing Chain and Chain Tensioner Components................................................................................................246 Timing Chain and Chain Tensioner Removal and Installation..................................................................................246 Timing Chain and Chain Tensioner Inspection................................................................................................249 Camshaft, Tappet and Shim Components.......................................................................................................250 Camshaft, Tappet and Shim Removal and Installation.........................................................................................251 Camshaft, Tappet and Shim Inspection.......................................................................................................253 Valves and Cylinder Head Components........................................................................................................256 Valves and Cylinder Head Removal and Installation..........................................................................................257 Valves and Cylinder Head Disassembly and Assembly..........................................................................................258 Valves and Valve Guides Inspection.........................................................................................................261 Cylinder Head Inspection...................................................................................................................263 Valve Spring Inspection....................................................................................................................265 Pistons, Piston Rings, Connecting Rods and Cylinders Components............................................................................266 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation..............................................................266 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly..............................................................268 Cylinders, Pistons and Piston Rings Inspection.............................................................................................269 Piston Pins and Connecting Rods Inspection.................................................................................................271 Crank Pin and Connecting Rod Bearings Inspection...........................................................................................273 Main Bearings, Crankshaft and Cylinder Block Components....................................................................................276 Main Bearings, Crankshaft and Cylinder Block Removal and Installation......................................................................277 Crankshaft Inspection......................................................................................................................280 Main Bearings Inspection...................................................................................................................281 Sensor Plate Inspection....................................................................................................................286 Rear Oil Seal Inspection...................................................................................................................286 Flywheel Inspection........................................................................................................................287 Cylinder Block Inspection..................................................................................................................287 Specifications.................................................................................................................................288 Tightening Torque Specifications...........................................................................................................288 Special Tools and Equipment....................................................................................................................289 Recommended Service Material...............................................................................................................289 Special Tool...............................................................................................................................289 Engine Lubrication System..........................................................................................................................291 General Description............................................................................................................................291 Engine Lubrication Description.............................................................................................................291 Diagnostic Information and Procedures..........................................................................................................292 Oil Pressure Check.........................................................................................................................292 Repair Instructions............................................................................................................................293 Oil Pan and Oil Pump Strainer Components...................................................................................................293 Oil Pan and Oil Pump Strainer Removal and Installation.....................................................................................294 Oil Pan and Oil Pump Strainer Cleaning.....................................................................................................296 Oil Pump Components........................................................................................................................296 Oil Pump Removal and Installation..........................................................................................................297 Oil Pump Disassembly and Reassembly........................................................................................................297 Oil Pump Inspection........................................................................................................................298 Specifications.................................................................................................................................299 Tightening Torque Specifications...........................................................................................................299 Special Tools and Equipment....................................................................................................................300 Recommended Service Material...............................................................................................................300 Special Tool...............................................................................................................................300 Engine Cooling System..............................................................................................................................301 General Description............................................................................................................................301 Coolant Description........................................................................................................................301 Schematic and Routing Diagram..................................................................................................................302 Coolant Circulation........................................................................................................................302 Diagnostic Information and Procedures..........................................................................................................303 Engine Cooling Symptom Diagnosis...........................................................................................................303 Repair Instructions............................................................................................................................304 Cooling System Components..................................................................................................................304 Thermostat Removal and Installation........................................................................................................305 Radiator Cooling Fan On-Vehicle Inspection.................................................................................................305 Water Pump / Generator Drive Belt Tension Inspection and Adjustment........................................................................306 Water Pump / Generator Drive Belt Removal and Installation.................................................................................306 Water Pump Removal and Installation........................................................................................................307 Specifications.................................................................................................................................308 Tightening Torque Specifications...........................................................................................................308 Special Tools and Equipment....................................................................................................................308 Recommended Service Material...............................................................................................................308 Fuel System........................................................................................................................................309 Precautions....................................................................................................................................309 Precautions on Fuel System Service.........................................................................................................309 General Description............................................................................................................................309 Fuel System Description....................................................................................................................309 Fuel Delivery System Description...........................................................................................................309 Fuel Pump Description......................................................................................................................310 Schematic and Routing Diagram..................................................................................................................310 Fuel Delivery System Diagram...............................................................................................................310 Diagnostic Information and Procedures..........................................................................................................311 Fuel Pressure Inspection...................................................................................................................311 Repair Instructions............................................................................................................................312 Fuel System Components.....................................................................................................................312 Fuel Hose Disconnecting and Reconnecting...................................................................................................313 Fuel Pressure Relief Procedure.............................................................................................................315 Fuel Leakage Check Procedure...............................................................................................................316 Fuel Lines On-Vehicle Inspection...........................................................................................................316 Fuel Pipe Removal and Installation.........................................................................................................316 Fuel Injector On-Vehicle Inspection........................................................................................................317 Fuel Injector Removal and Installation.....................................................................................................317 Fuel Injector Inspection...................................................................................................................318 Fuel Tank Removal and Installation.........................................................................................................320 Fuel Tank Purging Procedure................................................................................................................322 Fuel Tank Pressure Control Valve Removal and Installation..................................................................................322 Fuel Tank Pressure Control Valve Inspection................................................................................................323 Fuel Pump On-Vehicle Inspection............................................................................................................323 Fuel Pump Assembly Components..............................................................................................................323 Fuel Pump Assembly Removal and Installation................................................................................................324 Fuel Pump Assembly Inspection..............................................................................................................325 Fuel Pump Assembly Disassembly and Reassembly..............................................................................................326 Specifications.................................................................................................................................326 Tightening Torque Specifications...........................................................................................................326 Special Tools and Equipment....................................................................................................................327 Special Tool...............................................................................................................................327 Ignition System....................................................................................................................................328 General Description............................................................................................................................328 Ignition System Construction...............................................................................................................328 Schematic and Routing Diagram..................................................................................................................329 Ignition System Wiring Circuit Diagram.....................................................................................................329 Component Location.............................................................................................................................330 Ignition System Components Location........................................................................................................330 Diagnostic Information and Procedures..........................................................................................................331 Ignition System Symptom Diagnosis..........................................................................................................331 Reference Waveform of Ignition System......................................................................................................331 Ignition System Check......................................................................................................................331 Ignition Spark Test........................................................................................................................333 Repair Instructions............................................................................................................................333 High-Tension Cord Removal and Installation.................................................................................................333 High-Tension Cord Inspection...............................................................................................................334 Spark Plug Removal and Installation........................................................................................................334 Spark Plug Inspection......................................................................................................................335 Ignition Coil Assembly (Including Igniter) Removal and Installation........................................................................335 Ignition Coil Assembly (Including Igniter) Inspection......................................................................................336 Ignition Timing Inspection.................................................................................................................336 Specifications.................................................................................................................................337 Tightening Torque Specifications...........................................................................................................337 Special Tools and Equipment....................................................................................................................337 Special Tool...............................................................................................................................337 Exhaust System.....................................................................................................................................338 Repair Instructions............................................................................................................................338 Exhaust System Components..................................................................................................................338 Exhaust Manifold Removal and Installation..................................................................................................339 Specifications.................................................................................................................................340 Tightening Torque Specifications...........................................................................................................340 Suspension.............................................................................................................................................342 Suspension General Diagnosis.......................................................................................................................344 Specifications.................................................................................................................................344 Wheel Alignment Specifications.............................................................................................................344 Driveline / Axle.......................................................................................................................................346 Drive Shaft / Axle.................................................................................................................................348 Front..........................................................................................................................................348 Repair Instructions........................................................................................................................348 Front Drive Shaft Components...........................................................................................................348 Front Drive Shaft Disassembly and Assembly.............................................................................................349 Specifications.............................................................................................................................355 Tightening Torque Specifications.......................................................................................................355 Special Tools and Equipment................................................................................................................355 Recommended Service Material...........................................................................................................355 Special Tool...........................................................................................................................355 Brakes.................................................................................................................................................356 Brake Control System and Diagnosis.................................................................................................................358 Repair Instructions............................................................................................................................358 Master Cylinder Reservoir Removal and Installation.........................................................................................358 Master Cylinder Assembly Removal and Installation..........................................................................................359 Specifications.................................................................................................................................360 Tightening Torque Specifications...........................................................................................................360 Special Tools and Equipment....................................................................................................................360 Special Tool...............................................................................................................................360 Transmission / Transaxle...............................................................................................................................362 Automatic Transmission/Transaxle...................................................................................................................365 Precautions....................................................................................................................................365 Precautions in Diagnosing Trouble..........................................................................................................365 General Description............................................................................................................................365 On-Board Diagnostic System Description.....................................................................................................365 CAN Communication System Description.......................................................................................................368 Schematic and Routing Diagram..................................................................................................................369 Transmission Control Module (TCM) Wiring Diagram...........................................................................................369 Automatic Gear Shift Table.................................................................................................................371 Component Location.............................................................................................................................372 Electronic Shift Control System Components Location........................................................................................372 Electronic Shift Control Input / Output Table..............................................................................................373 Diagnostic Information and Procedures..........................................................................................................374 DTC Table..................................................................................................................................374 DTC Check..................................................................................................................................376 DTC Clearance..............................................................................................................................377 Fail-Safe Table............................................................................................................................378 A/T Symptom Diagnosis......................................................................................................................380 No Gear Shift to O/D.......................................................................................................................389 No Lock-Up Occurs..........................................................................................................................390 DTC P0705 / 0707 (No.34): Transmission Range Sensor Circuit Malfunction / Transmission Range Sensor Circuit low............................391 DTC P0712 (No.38): Transmission Fluid Temperature Sensor Circuit Low.......................................................................393 DTC P0713 (No.36): Transmission Fluid Temperature Sensor Circuit High......................................................................394 DTC P0717 (No.14): Input / Turbine Speed Sensor Circuit Malfunction........................................................................396 DTC P0722 (No.31): Output Speed Sensor (VSS) Circuit No Signal.............................................................................398 DTC P0741 / P0742 (No.29): TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON.....................................................400 DTC P0751 / P0752 (No.17) / P0756 / P0757 (No.28): Shift Solenoid Malfunction..............................................................401 DTC P0787 (No.13): Shift / Timing Solenoid Control Circuit Low.............................................................................403 DTC P0788 (No.13): Shift / Timing Solenoid Control Circuit High............................................................................405 DTC P0962 (No.41): Pressure Control Solenoid Control Circuit Low...........................................................................407 DTC P0963 (No.42): Pressure Control Solenoid Control Circuit High..........................................................................409 DTC P0973 / P0976 (No.22 / No.24): Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low...............411 DTC P0974 / P0977 (No.21 / No.23): Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High..................................413 DTC P1702 (No.52): Internal Control Module Memory Check Sum Error..........................................................................415 DTC P1703 (No.86): Can Invalid Data - TCM..................................................................................................415 DTC P1774 (No.76): Control Module Communication Bus Off....................................................................................416 DTC P1775 (No.76): High Speed CAN Communication Bus Off (Transmission Error)...............................................................417 DTC P1777 (No.76): TCM Lost Communication with ECM (Reception Error).......................................................................418 DTC P2769 (No.26): Torque Converter Clutch Circuit Low.....................................................................................419 DTC P2770 (No.25): Torque Converter Clutch Circuit High....................................................................................421 Inspection of TCM and Its Circuits.........................................................................................................423 TCM Power and Ground Circuit Check.........................................................................................................427 “O/D OFF” Lamp Circuit Check...............................................................................................................428 Repair Instructions............................................................................................................................431 Learning Control Initialization............................................................................................................431 A/T Fluid Level Check......................................................................................................................432 A/T Fluid Change...........................................................................................................................433 Select Cable Components....................................................................................................................433 Transmission Range Sensor (Shift Switch) Inspection and Adjustment.........................................................................434 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Timing Solenoid Valve) Inspection...........................................434 A/T Relay Inspection.......................................................................................................................436 A/T Fluid Cooler Hoses Replacement.........................................................................................................436 Automatic Transaxle Unit Components........................................................................................................437 Automatic Transaxle Unit Dismounting and Remounting........................................................................................438 Automatic Transaxle Assembly Components....................................................................................................440 Specifications.................................................................................................................................442 Tightening Torque Specifications...........................................................................................................442 Special Tools and Equipment....................................................................................................................442 Recommended Service Material...............................................................................................................442 Special Tool...............................................................................................................................442 Clutch.............................................................................................................................................443 Diagnostic Information and Procedures..........................................................................................................443 Clutch System Symptom Diagnosis............................................................................................................443 Repair Instructions............................................................................................................................444 Clutch Fluid Inspection (For LH Steering Vehicle)..........................................................................................444 Clutch Fluid Inspection (For RH Steering Vehicle)..........................................................................................444 Air Bleeding of Clutch System..............................................................................................................444 Clutch Fluid Pipe and Hose Components......................................................................................................445 Clutch Fluid Pipe and Hose Removal and Installation........................................................................................445 Clutch Master Cylinder Removal and Installation............................................................................................446 Clutch Master Cylinder Components..........................................................................................................448 Clutch Master Cylinder Disassembly and Reassembly..........................................................................................448 Specifications.................................................................................................................................449 Tightening Torque Specifications...........................................................................................................449 Special Tools and Equipment....................................................................................................................449 Recommended Service Material...............................................................................................................449 HVAC...................................................................................................................................................450 Heater and Ventilation.............................................................................................................................453 Schematic and Routing Diagram..................................................................................................................453 Heater and Ventilation Wiring Circuit Diagram..............................................................................................453 Diagnostic Information and Procedures..........................................................................................................454 Inspection of HVAC Control Module and its Circuit..........................................................................................454 Repair Instructions............................................................................................................................456 Blower Unit Components.....................................................................................................................456 HVAC Air Filter Removal and Installation (If Equipped).....................................................................................457 HVAC Air Filter Inspection (If Equipped)...................................................................................................457 Air Conditioning System............................................................................................................................458 Manual Type....................................................................................................................................458 Schematic and Routing Diagram..............................................................................................................458 A/C System Wiring Diagram..............................................................................................................458 Diagnostic Information and Procedures......................................................................................................459 Inspection of HVAC Control Module and its Circuit......................................................................................459 A/C System Inspection at ECM...........................................................................................................461 Repair Instructions........................................................................................................................461 Operation Procedure for Refrigerant Charging...........................................................................................461 Special Tools and Equipment................................................................................................................466 Special Tool...........................................................................................................................466 Automatic Type.................................................................................................................................467 Schematic and Routing Diagram..............................................................................................................467 A/C System Wiring Diagram..............................................................................................................467 Diagnostic Information and Procedures......................................................................................................468 DTC B1510 (No.10): Engine Coolant Temperature (ECT) Sensor and/or its Circuit Malfunction..............................................468 Inspection of HVAC Control Module and its Circuit......................................................................................469 A/C System Inspection at ECM...........................................................................................................471 Body, Cab and Accessories..............................................................................................................................472 Wiring Systems.....................................................................................................................................476 General Description............................................................................................................................476 Abbreviations..............................................................................................................................476 Symbols and Marks..........................................................................................................................477 How to Read Connector Codes and Terminal Nos...............................................................................................479 How to Read Ground Point...................................................................................................................481 How to Read Power Supply Diagram...........................................................................................................482 How to Read System Circuit Diagram.........................................................................................................483 Harness Routing and Connector Layout Diagram...................................................................................................484 Connector Layout Diagram...................................................................................................................484 Engine Compartment for Connector Layout Diagram............................................................................................485 Instrument Panel for Connector Layout Diagram..............................................................................................495 Door, Roof for Connector Layout Diagram....................................................................................................501 Floor for Connector Layout Diagram.........................................................................................................503 Rear for Connector Layout Diagram..........................................................................................................511 Ground Point...................................................................................................................................513 Ground (earth) Point.......................................................................................................................513 Power Supply Diagram...........................................................................................................................515 Power Supply Diagram.......................................................................................................................515 Fuses and the Protected Parts..............................................................................................................517 Fuses in Main Fuse Box.....................................................................................................................517 Individual Circuit Fuse Box, Supplementary Fuse Box (No. 1), Supplementary Fuse Box (No. 2)................................................518 System Circuit Diagram.........................................................................................................................520 System Circuit Diagram.....................................................................................................................520 A-1 Cranking System Circuit Diagram........................................................................................................521 A-2 Charging System Circuit Diagram........................................................................................................522 A-3 Ignition System Circuit Diagram........................................................................................................523 A-4 Cooling System Circuit Diagram.........................................................................................................524 A-5 Engine and A/C Control System Circuit Diagram (Euro 4 of EU/Taiwan)....................................................................525 A-5 Engine and A/C Control System Circuit Diagram (Except Euro 4 of EU/Taiwan).............................................................529 A-6 4 A/T Control System Circuit Diagram...................................................................................................533 A-7 Immobilizer Control System Circuit Diagram.............................................................................................535 B-1 Windshield Wiper and Washer Circuit Diagram............................................................................................536 B-2 Rear Wiper and Washer Circuit Diagram..................................................................................................537 B-3 Rear Defogger Circuit Diagram..........................................................................................................538 B-4 Power Window Circuit Diagram...........................................................................................................539 B-5 Power Door Lock Circuit Diagram........................................................................................................541 B-6 Power Mirror Circuit Diagram...........................................................................................................543 B-7 Horn Circuit Diagram...................................................................................................................544 B-8 Seat Heater Circuit Diagram............................................................................................................545 C-1 Combination Meter Circuit Diagram (Meter)..............................................................................................546 C-2 Combination Meter Circuit Diagram (Indicator)..........................................................................................547 C-3 Combination Meter Circuit Diagram (Warning Light)......................................................................................548 D-1 Headlight System Circuit Diagram.......................................................................................................550 D-2 Position, Tail and Licence Plate Light Circuit Diagram.................................................................................552 D-3 Fog Light Circuit Diagram..............................................................................................................553 D-4 Illumination Light Circuit Diagram.....................................................................................................554 D-5 Interior Light Circuit Diagram.........................................................................................................555 D-6 Turn Signal and Hazard Warning Light Circuit Diagram...................................................................................556 D-7 Brake Light Circuit Diagram............................................................................................................557 D-8 Back-Up Light Circuit Diagram..........................................................................................................558 D-9 Headlight Beam Leveling System Circuit Diagram.........................................................................................559 D-10 Rear fog light Circuit Diagram........................................................................................................560 E-1 Heater and Air Conditioner Circuit Diagram.............................................................................................561 E-2 Auto A/C System Circuit Diagram........................................................................................................563 F-1 Air-Bag Control System Circuit Diagram.................................................................................................565 F-2 Anti-Lock Brake System Circuit Diagram.................................................................................................567 G-1 Audio / Cigar Lighter Circuit Diagram..................................................................................................569 G-2 Clock Circuit Diagram..................................................................................................................571 List of Connectors.............................................................................................................................572 List of Connector..........................................................................................................................572 C Connector................................................................................................................................572 E Connector................................................................................................................................573 G Connector................................................................................................................................575 J Connector................................................................................................................................577 K Connector................................................................................................................................578 L Connector................................................................................................................................578 M Connector................................................................................................................................580 O Connector................................................................................................................................580 Instrumentation / Driver Info. / Horn..............................................................................................................581 Schematic and Routing Diagram..................................................................................................................581 Combination Meter Circuit Diagram..........................................................................................................581 Diagnostic Information and Procedures..........................................................................................................582 Speedometer and VSS Symptom Diagnosis......................................................................................................582 Information Display (If Equipped) Symptom Diagnosis........................................................................................583 Repair Instructions............................................................................................................................584 VSS Inspection.............................................................................................................................584 Remote Audio Control Switch Inspection.....................................................................................................584 Control systems........................................................................................................................................586 Immobilizer Control System.........................................................................................................................587 Precautions....................................................................................................................................587 Precautions in Diagnosing Troubles.........................................................................................................587 General Description............................................................................................................................588 Immobilizer Control System Introduction....................................................................................................588 On-Board Diagnostic System Description (Self- diagnosis Function)..........................................................................589 Schematic and Routing Diagram..................................................................................................................590 Immobilizer Control System Wiring Circuit Diagram..........................................................................................590 Diagnostic Information and Procedures..........................................................................................................591 Immobilizer Control System Check...........................................................................................................591 DTC Check..................................................................................................................................592 DTC Table..................................................................................................................................593 Immobilizer Indicator Lamp Does Not Light at Ignition Switch ON............................................................................594 Immobilizer Indicator Lamp Remains ON after Engine Starts..................................................................................595 DTC Is Not Output from Immobilizer Control Module..........................................................................................596 DTC 13: No Transponder Code Transmitted or Coil Antenna Opened/Shorted.....................................................................598 DTC 22: Ignition Switch Circuit Open/Short.................................................................................................599 DTC 23 / 83 (P1621): No ECM/Immobilizer Control Module Code Transmitted or DLC Circuit Opened/ Shorted.....................................600 Special Tools and Equipment....................................................................................................................601 Special Tool...............................................................................................................................601 COPYRIGHT..............................................................................................................................................602 BOOKCOVER..............................................................................................................................................603
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