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SUZUKI RH418 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
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“Suzuki RH418 Liana Service Manual Vol 1 & 2” provides detailed instructions for maintenance and repair, ensuring precise care for optimal performance of the specific model.
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SUZUKI RH418 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RH418 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
Language : English
Pages : 1258
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
SUZUKI RH418 LIANA SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
Bookcover_vol1.......................................................................................................................................................................... 1 BOOKCOVER_VOL1...................................................................................................................................................................... 1 Bookcover_vol2.......................................................................................................................................................................... 2 99500_54G20_24E......................................................................................................................................................................... 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..................................................................................................................................... 16 Precautions for Electrical Circuit Service.............................................................................................................................. 16 Precautions for Installing Mobile Communication Equipment............................................................................................................... 18 Precautions for Vehicle Tie-Down Hooks.................................................................................................................................. 19 Precautions in Servicing Full-Time 4WD Vehicle.......................................................................................................................... 20 Air Bag Warning......................................................................................................................................................... 21 Air Bag System Service Warning.......................................................................................................................................... 21 Fastener Caution........................................................................................................................................................ 21 Suspension Caution...................................................................................................................................................... 21 Wheels and Tires Note................................................................................................................................................... 22 Brake Note.............................................................................................................................................................. 22 Repair Instructions......................................................................................................................................................... 22 Electrical Circuit Inspection Procedure................................................................................................................................. 22 Intermittent and Poor Connection Inspection............................................................................................................................. 24 General Information................................................................................................................................................................. 27 General Information............................................................................................................................................................. 28 General Description......................................................................................................................................................... 28 Abbreviations........................................................................................................................................................... 28 Symbols................................................................................................................................................................. 29 Wire Color Symbols...................................................................................................................................................... 30 Fasteners Information................................................................................................................................................... 30 Vehicle Lifting Points.................................................................................................................................................. 32 Vehicle Identification Number........................................................................................................................................... 34 Engine Identification Number............................................................................................................................................ 34 Transmission Identification Number...................................................................................................................................... 34 Component Location.......................................................................................................................................................... 35 Warning, Caution and Information Labels Location........................................................................................................................ 35 Maintenance and Lubrication..................................................................................................................................................... 37 Precautions................................................................................................................................................................. 37 Precautions for Maintenance and Lubrication............................................................................................................................. 37 Scheduled Maintenance....................................................................................................................................................... 37 Normal Condition Schedule............................................................................................................................................... 37 Maintenance Recommended under Severe Driving Conditions................................................................................................................. 38 Repair Instructions......................................................................................................................................................... 39 Drive Belt Inspection................................................................................................................................................... 39 Drive Belt Replacement.................................................................................................................................................. 40 Valve Lash (Clearance) Inspection....................................................................................................................................... 40 Engine Oil and Filter Change............................................................................................................................................ 40 Engine Coolant Change................................................................................................................................................... 41 Exhaust System Inspection............................................................................................................................................... 41 Spark Plugs Replacement................................................................................................................................................. 42 Air Cleaner Filter Inspection........................................................................................................................................... 42 Air Cleaner Filter Replacement.......................................................................................................................................... 42 Fuel Lines and Connections Inspection................................................................................................................................... 42 Fuel Filter Replacement................................................................................................................................................. 42 Fuel Tank Inspection.................................................................................................................................................... 42 PCV Valve Inspection.................................................................................................................................................... 42 Fuel Evaporative Emission Control System Inspection..................................................................................................................... 43 Brake Discs and Pads (Front) Inspection................................................................................................................................. 43 Brake Drums and Shoes (Rear) Inspection................................................................................................................................. 43 Brake Hoses and Pipes Inspection........................................................................................................................................ 43 Brake Fluid Replacement................................................................................................................................................. 43 Brake Lever and Cable Inspection........................................................................................................................................ 44 Clutch Fluid Inspection................................................................................................................................................. 44 Tires / Wheels Inspection............................................................................................................................................... 44 Wheel Discs Inspection.................................................................................................................................................. 44 Wheel Bearing Inspection................................................................................................................................................ 44 Suspension System Inspection............................................................................................................................................ 45 Steering System Inspection.............................................................................................................................................. 45 Drive Shaft (Axle) Boots Inspection..................................................................................................................................... 46 Manual Transaxle Oil Inspection......................................................................................................................................... 46 Manual Transaxle Oil Replacement........................................................................................................................................ 46 Automatic Transaxle Fluid Inspection.................................................................................................................................... 46 Automatic Transaxle Fluid Replacement................................................................................................................................... 46 Automatic Transaxle Fluid Cooler Hose Inspection........................................................................................................................ 47 All Latches, Hinges and Locks Inspection................................................................................................................................ 47 Power Steering (P/S) System Inspection.................................................................................................................................. 47 HVAC Air Filter (If Equipped) Inspection................................................................................................................................ 47 HVAC Air Filter (If Equipped) Replacement............................................................................................................................... 48 Final Inspection for Maintenance Service................................................................................................................................ 48 Specifications.............................................................................................................................................................. 49 Tightening Torque Specifications........................................................................................................................................ 49 Special Tools and Equipment................................................................................................................................................. 49 Recommended Fluids and Lubricants....................................................................................................................................... 49 Special Tool............................................................................................................................................................ 49 Engine.............................................................................................................................................................................. 51 Precautions..................................................................................................................................................................... 55 Precautions................................................................................................................................................................. 55 Precautions for Engine.................................................................................................................................................. 55 Engine General Information and Diagnosis........................................................................................................................................ 56 Precautions................................................................................................................................................................. 56 Precautions on Engine Service........................................................................................................................................... 56 Precautions in Diagnosing Trouble....................................................................................................................................... 56 General Description......................................................................................................................................................... 57 Statement on Cleanliness and Care....................................................................................................................................... 57 Engine Diagnosis General Description.................................................................................................................................... 57 On-Board Diagnostic System Description.................................................................................................................................. 57 Engine and Emission Control System Description.......................................................................................................................... 59 Air Intake System Description........................................................................................................................................... 60 Electronic Control System Description................................................................................................................................... 60 Engine and Emission Control Input / Output Table........................................................................................................................ 65 Schematic and Routing Diagram............................................................................................................................................... 66 Engine and Emission Control System Diagram.............................................................................................................................. 66 Component Location.......................................................................................................................................................... 67 Electronic Control System Components Location........................................................................................................................... 67 Diagnostic Information and Procedures....................................................................................................................................... 68 Engine and Emission Control System Check................................................................................................................................ 68 Malfunction Indicator Lamp (MIL) Check.................................................................................................................................. 71 DTC Check............................................................................................................................................................... 72 DTC Clearance........................................................................................................................................................... 72 DTC Table............................................................................................................................................................... 73 Fail-Safe Table......................................................................................................................................................... 76 Scan Tool Data.......................................................................................................................................................... 77 Visual Inspection....................................................................................................................................................... 82 Engine Basic Inspection................................................................................................................................................. 82 Engine Symptom Diagnosis................................................................................................................................................ 85 Malfunction Indicator Lamp Does Not Come ON While Ignition Switch Is Turned ON with Engine at Stop (But Engine Can Be Stared)........................................... 92 Malfunction Indicator Lamp Remains ON after Engine Starts............................................................................................................... 93 DTC P0010: Camshaft Position Actuator Circuit........................................................................................................................... 94 DTC P0011 / P0012: Camshaft Position-Timing Over-Advanced or System Performance / Timing Over-Retarded.................................................................. 96 DTC P0107: Manifold Absolute Pressure Circuit Low Input................................................................................................................. 98 DTC P0108: Manifold Absolute Pressure Circuit High Input................................................................................................................ 100 DTC P0112: Intake Air Temperature Sensor Circuit Low.................................................................................................................... 102 DTC P0113: Intake Air Temperature Sensor Circuit High................................................................................................................... 104 DTC P0117: Engine Coolant Temperature Circuit Low....................................................................................................................... 106 DTC P0118: Engine Coolant Temperature Circuit High...................................................................................................................... 108 DTC P0121: Throttle Position Sensor Circuit Range / Performance......................................................................................................... 110 DTC P0122: Throttle Position Sensor Circuit Low......................................................................................................................... 113 DTC P0123: Throttle Position Sensor Circuit High........................................................................................................................ 115 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)....................................................................................... 118 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)............................................................................................................ 121 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)..................................................................................................... 122 DTC P0135: O2 Sensor (HO2S) Heater Circuit (Sensor-1)................................................................................................................... 124 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)..................................................................................................... 125 DTC P0141: O2 Sensor (HO2S) Heater Circuit (Sensor-2)................................................................................................................... 127 DTC P0171 / P0172: Fuel System Too Lean / Rich.......................................................................................................................... 129 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected................................. 130 DTC P0327 / P0328: Knock Sensor Circuit Low / High...................................................................................................................... 132 DTC P0335: Crankshaft Position (CKP) Sensor Circuit..................................................................................................................... 134 DTC P0340: Camshaft Position (CMP) Sensor Circuit....................................................................................................................... 136 DTC P0420: Catalyst System Efficiency below Threshold................................................................................................................... 138 DTC P0443: Evaporative Emission System Purge Control Valve Circuit...................................................................................................... 140 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit................................................................................................................. 142 DTC P0500: Vehicle Speed Sensor (VSS)................................................................................................................................... 145 DTC P0505: Idle Air Control System...................................................................................................................................... 147 DTC P0601 / P0602: Internal Control Module Memory Check Sum Error / Control Module Programming Error.................................................................... 149 DTC P0616: Starter Relay Circuit Low.................................................................................................................................... 150 DTC P0617: Starter Relay Circuit High................................................................................................................................... 151 DTC P1510: ECM Back-Up Power Supply Malfunction......................................................................................................................... 152 DTC P1600: Serial Communication Problem between ECM and TCM............................................................................................................. 153 DTC P1717: A/T Drive Range (Park/Neutral Position) Signal Circuit Malfunction........................................................................................... 155 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction...................................................................................................... 157 Inspection of ECM and Its Circuits...................................................................................................................................... 158 ECM Power and Ground Circuit Check...................................................................................................................................... 171 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................................................................................................................................ 180 A/C Control System Check (Vehicle with A/C)............................................................................................................................. 181 Electric Load Signal Circuit Check...................................................................................................................................... 184 Radiator Cooling Fan Low Speed Control System Check..................................................................................................................... 186 Radiator Cooling Fan High Speed Control System Check.................................................................................................................... 188 Power Steering Pressure (PSP) Switch Signal Circuit Check............................................................................................................... 190 Generator Control Signal Circuit Check.................................................................................................................................. 191 Repair Instructions......................................................................................................................................................... 192 Idle Speed / Idle Air Control (IAC) Duty Inspection..................................................................................................................... 192 Special Tools and Equipment................................................................................................................................................. 193 Special Tool............................................................................................................................................................ 193 Aux. Emission Control Devices................................................................................................................................................... 194 Repair Instructions......................................................................................................................................................... 194 EVAP Canister Inspection................................................................................................................................................ 194 EVAP Canister Purge Inspection.......................................................................................................................................... 194 EVAP Canister Purge Valve and Its Circuit Inspection.................................................................................................................... 195 EVAP Canister Purge Valve Inspection.................................................................................................................................... 195 Vacuum Passage Inspection............................................................................................................................................... 196 Vacuum Hose Inspection.................................................................................................................................................. 196 PCV Hose Inspection..................................................................................................................................................... 196 PCV Valve Inspection.................................................................................................................................................... 197 Special Tools and Equipment................................................................................................................................................. 197 Special Tool............................................................................................................................................................ 197 Engine Electrical Devices....................................................................................................................................................... 198 Repair Instructions......................................................................................................................................................... 198 Idle Air Control (IAC) Valve Removal and Installation................................................................................................................... 198 Idle Air Control (IAC) Valve Inspection................................................................................................................................. 198 Engine Control Module (ECM) Removal and Installation.................................................................................................................... 198 Manifold Absolute Pressure (MAP) Sensor Inspection...................................................................................................................... 199 Throttle Position (TP) Sensor On-Vehicle Inspection..................................................................................................................... 199 Throttle Position (TP) Sensor Removal and Installation.................................................................................................................. 200 Intake Air Temperature (IAT) Sensor Removal and Installation............................................................................................................ 200 Intake Air Temperature (IAT) Sensor Inspection.......................................................................................................................... 201 Engine Coolant Temperature (ECT) Sensor Removal and Installation........................................................................................................ 201 Engine Coolant Temperature (ECT) Sensor Inspection...................................................................................................................... 202 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation....................................................................................................... 202 Oxygen Sensor (HO2S-1 and HO2S-2) Heater Inspection..................................................................................................................... 203 Camshaft Position (CMP) Sensor Removal and Installation................................................................................................................. 203 Camshaft Position (CMP) Sensor Inspection............................................................................................................................... 203 Crankshaft Position (CKP) Sensor Removal and Installation............................................................................................................... 204 Crankshaft Position (CKP) Sensor Inspection............................................................................................................................. 204 Vehicle Speed Sensor (VSS) Inspection................................................................................................................................... 205 Knock Sensor Removal and Installation................................................................................................................................... 205 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....................................................................................................................... 206 Specifications.............................................................................................................................................................. 207 Tightening Torque Specifications........................................................................................................................................ 207 Engine Mechanical............................................................................................................................................................... 208 General Description......................................................................................................................................................... 208 Engine Construction Description......................................................................................................................................... 208 Camshaft Position Control (VVT Variable Valve Timing) System Description................................................................................................ 209 Diagnostic Information and Procedures....................................................................................................................................... 212 Compression Check....................................................................................................................................................... 212 Engine Vacuum Check..................................................................................................................................................... 213 Valve Lash (Clearance) Inspection....................................................................................................................................... 214 Repair Instructions......................................................................................................................................................... 217 Air Cleaner Filter Removal and Installation............................................................................................................................. 217 Air Cleaner Filter Inspection and Cleaning.............................................................................................................................. 217 Accelerator Cable Adjustment............................................................................................................................................ 217 Throttle Body and Intake Manifold Components............................................................................................................................ 218 Throttle Body On-Vehicle Inspection..................................................................................................................................... 218 Throttle Body Removal and Installation.................................................................................................................................. 218 Throttle Body Disassembly and Assembly.................................................................................................................................. 219 Throttle Body Cleaning.................................................................................................................................................. 220 Throttle Body and Intake Manifold Removal and Installation.............................................................................................................. 220 Cylinder Head Cover Removal and Installation............................................................................................................................ 221 Engine Mountings Components............................................................................................................................................. 223 Engine Assembly Removal and Installation................................................................................................................................ 224 Timing Chain Cover Components........................................................................................................................................... 227 Timing Chain Cover Removal and Installation............................................................................................................................. 228 Timing Chain Cover Inspection........................................................................................................................................... 230 Oil Control Valve Removal and Installation.............................................................................................................................. 231 Oil Control Valve Inspection............................................................................................................................................ 231 Timing Chain and Chain Tensioner Components............................................................................................................................. 232 Timing Chain and Chain Tensioner Removal and Installation............................................................................................................... 232 Timing Chain and Chain Tensioner Inspection............................................................................................................................. 235 Camshaft, Tappet and Shim Components.................................................................................................................................... 236 Camshaft, Tappet and Shim Removal and installation...................................................................................................................... 236 Camshaft, Tappet and shim Inspection.................................................................................................................................... 239 Valves and Cylinder Head Components..................................................................................................................................... 242 Valves and Cylinder Head Removal and Installation....................................................................................................................... 243 Valves and Cylinder Head Disassembly and Assembly....................................................................................................................... 244 Valves and Valve Guides Inspection...................................................................................................................................... 247 Cylinder Head Inspection................................................................................................................................................ 249 Valve Spring Inspection................................................................................................................................................. 250 Pistons, Piston Rings and Connecting Rods Components.................................................................................................................... 251 Pistons, Piston Rings and Connecting Rods Removal and Installation...................................................................................................... 251 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly........................................................................................... 253 Cylinders, Pistons and Piston Rings Inspection.......................................................................................................................... 254 Piston Pins and Connecting Rods Inspection.............................................................................................................................. 256 Crank Pin and Connecting Rod Bearings Inspection........................................................................................................................ 257 Main Bearings, Crankshaft and Cylinder Block Components................................................................................................................. 261 Main Bearings, Crankshaft and Cylinder Block Removal and Installation................................................................................................... 262 Crankshaft Inspection................................................................................................................................................... 265 Main Bearings Inspection................................................................................................................................................ 267 Sensor Plate Inspection................................................................................................................................................. 270 Rear Oil Seal Inspection................................................................................................................................................ 270 Flywheel Inspection..................................................................................................................................................... 271 Cylinder Block Inspection............................................................................................................................................... 271 Specifications.............................................................................................................................................................. 272 Tightening Torque Specifications........................................................................................................................................ 272 Special Tools and Equipment................................................................................................................................................. 273 Recommended Service Material............................................................................................................................................ 273 Special Tool............................................................................................................................................................ 273 Engine Lubrication System....................................................................................................................................................... 275 General Description......................................................................................................................................................... 275 Engine Lubrication Description.......................................................................................................................................... 275 Diagnostic Information and Procedures....................................................................................................................................... 276 Oil Pressure Check...................................................................................................................................................... 276 Repair Instructions......................................................................................................................................................... 277 Oil Pan and Oil Pump Strainer Components................................................................................................................................ 277 Oil Pan and Oil Pump Strainer Removal and Installation.................................................................................................................. 278 Oil Pan and Oil Pump Strainer Cleaning.................................................................................................................................. 280 Oil Pump Components..................................................................................................................................................... 280 Oil Pump Removal and Installation....................................................................................................................................... 281 Oil Pump Disassembly and Reassembly..................................................................................................................................... 281 Oil Pump Inspection..................................................................................................................................................... 282 Specifications.............................................................................................................................................................. 283 Tightening Torque Specifications........................................................................................................................................ 283 Special Tools and Equipment................................................................................................................................................. 284 Recommended Service Material............................................................................................................................................ 284 Special Tool............................................................................................................................................................ 284 Engine Cooling System........................................................................................................................................................... 285 General Description......................................................................................................................................................... 285 Cooling System Description.............................................................................................................................................. 285 Coolant Description..................................................................................................................................................... 285 Schematic and Routing Diagram............................................................................................................................................... 286 Coolant Circulation..................................................................................................................................................... 286 Diagnostic Information and Procedures....................................................................................................................................... 288 Engine Cooling Symptom Diagnosis........................................................................................................................................ 288 Repair Instructions......................................................................................................................................................... 289 Cooling System Components............................................................................................................................................... 289 Coolant Level Check..................................................................................................................................................... 290 Engine Cooling System Inspection and Cleaning........................................................................................................................... 290 Cooling System Flush and Refill......................................................................................................................................... 291 Cooling Water Pipes or Hoses Removal and Installation................................................................................................................... 291 Thermostat Removal and Installation..................................................................................................................................... 292 Thermostat Inspection................................................................................................................................................... 292 Radiator Cooling Fan On-Vehicle Inspection.............................................................................................................................. 293 Radiator Cooling Fan Relay Inspection................................................................................................................................... 293 Radiator Cooling Fan Assembly Removal and Installation.................................................................................................................. 294 Radiator On-Vehicle Inspection and Cleaning............................................................................................................................. 294 Radiator Removal and Installation....................................................................................................................................... 294 Water Pump / Generator Drive Belt Tension Inspection and Adjustment..................................................................................................... 295 Water Pump / Generator Drive Belt Removal and Installation.............................................................................................................. 295 Water Pump Removal and Installation..................................................................................................................................... 296 Water Pump Inspection................................................................................................................................................... 297 Specifications.............................................................................................................................................................. 297 Tightening Torque Specifications........................................................................................................................................ 297 Special Tools and Equipment................................................................................................................................................. 297 Recommended Service Material............................................................................................................................................ 297 Fuel System..................................................................................................................................................................... 298 Precautions................................................................................................................................................................. 298 Precautions on Fuel System Service...................................................................................................................................... 298 General Description......................................................................................................................................................... 298 Fuel System Description................................................................................................................................................. 298 Fuel Delivery System Description........................................................................................................................................ 298 Fuel Pump Description................................................................................................................................................... 299 Schematic and Routing Diagram............................................................................................................................................... 299 Fuel Delivery System Diagram............................................................................................................................................ 299 Diagnostic Information and Procedures....................................................................................................................................... 300 Fuel Pressure Inspection................................................................................................................................................ 300 Fuel Cut Operation Inspection........................................................................................................................................... 301 Repair Instructions......................................................................................................................................................... 302 Fuel System Components.................................................................................................................................................. 302 Fuel Hose Disconnecting and Reconnecting................................................................................................................................ 303 Fuel Pressure Relief Procedure.......................................................................................................................................... 305 Fuel Leakage Check Procedure............................................................................................................................................ 306 Fuel Lines On-Vehicle Inspection........................................................................................................................................ 306 Fuel Pipe Removal and Installation...................................................................................................................................... 306 Fuel Injector On-Vehicle Inspection..................................................................................................................................... 307 Fuel Injector Removal and Installation.................................................................................................................................. 307 Fuel Injector Inspection................................................................................................................................................ 308 Fuel Pressure Regulator On-Vehicle Inspection........................................................................................................................... 310 Fuel Pressure Regulator Removal and Installation........................................................................................................................ 310 Fuel Filler Cap Inspection.............................................................................................................................................. 310 Fuel Tank Removal and Installation...................................................................................................................................... 311 Fuel Tank Inspection.................................................................................................................................................... 313 Fuel Tank Purging Procedure............................................................................................................................................. 313 Fuel Tank Inlet Valve Removal and Installation.......................................................................................................................... 314 Fuel Tank Inlet Valve Inspection........................................................................................................................................ 314 Fuel Tank Pressure Control Valve Removal and Installation............................................................................................................... 314 Fuel Tank Pressure Control Valve Inspection............................................................................................................................. 315 Fuel Pump On-Vehicle Inspection......................................................................................................................................... 315 Fuel Pump Assembly Components........................................................................................................................................... 315 Fuel Pump Assembly Removal and Installation............................................................................................................................. 316 Fuel Pump Assembly Inspection........................................................................................................................................... 317 Fuel Pump Assembly Disassembly and Reassembly........................................................................................................................... 318 Specifications.............................................................................................................................................................. 318 Tightening Torque Specifications........................................................................................................................................ 318 Special Tools and Equipment................................................................................................................................................. 319 Special Tool............................................................................................................................................................ 319 Ignition System................................................................................................................................................................. 320 General Description......................................................................................................................................................... 320 Ignition System Construction............................................................................................................................................ 320 Schematic and Routing Diagram............................................................................................................................................... 321 Ignition System Wiring Circuit Diagram.................................................................................................................................. 321 Component Location.......................................................................................................................................................... 322 Ignition System Components Location..................................................................................................................................... 322 Diagnostic Information and Procedures....................................................................................................................................... 322 Ignition System Symptom Diagnosis....................................................................................................................................... 322 Ignition System Check................................................................................................................................................... 323 Ignition Spark Test..................................................................................................................................................... 324 Repair Instructions......................................................................................................................................................... 324 High-Tension Cord Removal and Installation.............................................................................................................................. 324 High-Tension Cord Inspection............................................................................................................................................ 325 Spark Plug Removal and Installation..................................................................................................................................... 325 Spark Plug Inspection................................................................................................................................................... 326 Ignition Coil Assembly (Including Igniter) Removal and Installation..................................................................................................... 326 Ignition Coil Assembly (Including Igniter) Inspection................................................................................................................... 327 Ignition Timing Inspection.............................................................................................................................................. 327 Specifications.............................................................................................................................................................. 328 Tightening Torque Specifications........................................................................................................................................ 328 Special Tools and Equipment................................................................................................................................................. 328 Special Tool............................................................................................................................................................ 328 Starting System................................................................................................................................................................. 329 Schematic and Routing Diagram............................................................................................................................................... 329 Cranking System Circuit Diagram......................................................................................................................................... 329 Diagnostic Information and Procedures....................................................................................................................................... 329 Cranking System Symptom Diagnosis....................................................................................................................................... 329 Cranking System Test.................................................................................................................................................... 331 Repair Instructions......................................................................................................................................................... 332 Starting Motor Dismounting and Remounting............................................................................................................................... 332 Starting Motor Components............................................................................................................................................... 333 Starting Motor Inspection............................................................................................................................................... 334 Specifications.............................................................................................................................................................. 337 Cranking System Specifications.......................................................................................................................................... 337 Tightening Torque Specifications........................................................................................................................................ 337 Special Tools and Equipment................................................................................................................................................. 337 Recommended Service Material............................................................................................................................................ 337 Charging System................................................................................................................................................................. 338 General Description......................................................................................................................................................... 338 Battery Description..................................................................................................................................................... 338 Generator Description................................................................................................................................................... 340 Diagnostic Information and Procedures....................................................................................................................................... 341 Battery Inspection...................................................................................................................................................... 341 Generator Symptom Diagnosis............................................................................................................................................. 341 Generator Test (Undercharged Battery Check)............................................................................................................................. 342 Generator Test (Overcharged Battery Check).............................................................................................................................. 343 Repair Instructions......................................................................................................................................................... 343 Jump Starting in Case of Emergency...................................................................................................................................... 343 Battery Dismounting and Remounting...................................................................................................................................... 344 Generator Dismounting and Remounting.................................................................................................................................... 345 Generator Components.................................................................................................................................................... 346 Generator Inspection.................................................................................................................................................... 346 Specifications.............................................................................................................................................................. 348 Charging System Specifications.......................................................................................................................................... 348 Tightening Torque Specifications........................................................................................................................................ 348 Exhaust System.................................................................................................................................................................. 349 General Description......................................................................................................................................................... 349 Exhaust System Description.............................................................................................................................................. 349 Repair Instructions......................................................................................................................................................... 349 Exhaust System Components............................................................................................................................................... 349 Exhaust Manifold Removal and Installation............................................................................................................................... 350 Exhaust Pipe Removal and Installation................................................................................................................................... 351 Specifications.............................................................................................................................................................. 351 Tightening Torque Specifications........................................................................................................................................ 351 Suspension.......................................................................................................................................................................... 353 Precautions..................................................................................................................................................................... 355 Precautions................................................................................................................................................................. 355 Precautions on Suspension............................................................................................................................................... 355 Suspension General Diagnosis.................................................................................................................................................... 356 Diagnostic Information and Procedures....................................................................................................................................... 356 Suspension, Wheels and Tires Symptom Diagnosis.......................................................................................................................... 356 Specifications.............................................................................................................................................................. 358 Wheel Alignment Specifications.......................................................................................................................................... 358 Front Suspension................................................................................................................................................................ 359 General Description......................................................................................................................................................... 359 Front Suspension Construction........................................................................................................................................... 359 Front Wheel Alignment Construction...................................................................................................................................... 360 Repair Instructions......................................................................................................................................................... 360 Front Wheel Alignment Inspection and Adjustment......................................................................................................................... 360 Front Stabilizer Bar and/or Bushings Components......................................................................................................................... 362 Front Stabilizer Bar and/or Bushings Removal and Installation........................................................................................................... 362 Front Stabilizer Bar, Bushing and/or Joint Check........................................................................................................................ 363 Front Strut Assembly Components......................................................................................................................................... 364 Front Strut Assembly Removal and Installation........................................................................................................................... 365 Front Strut Assembly Disassembly and Assembly........................................................................................................................... 367 Front Strut Assembly Check.............................................................................................................................................. 368 Front Wheel Hub and Steering Knuckle Components......................................................................................................................... 369 Front Wheel Hub and Steering Knuckle Removal and Installation........................................................................................................... 369 Front Wheel Hub and Steering Knuckle Disassembly and Assembly........................................................................................................... 372 Front Wheel Disc, Nut and Bearing Check................................................................................................................................. 373 Suspension Control Arm / Bushing Removal and Installation............................................................................................................... 374 Suspension Control Arm / Bushing Disassembly and Assembly............................................................................................................... 375 Suspension Control Arm / Steering Knuckle Check......................................................................................................................... 376 Suspension Control Arm Bushing Check.................................................................................................................................... 376 Suspension Control Arm Joint Check...................................................................................................................................... 376 Front Suspension Frame Components....................................................................................................................................... 376 Front Suspension Frame Removal and Installation......................................................................................................................... 377 Front Suspension Frame Check............................................................................................................................................ 378 Front Suspension Fasteners Check........................................................................................................................................ 378 Specifications.............................................................................................................................................................. 379 Tightening Torque Specifications........................................................................................................................................ 379 Special Tools and Equipment................................................................................................................................................. 380 Special Tool............................................................................................................................................................ 380 Rear Suspension................................................................................................................................................................. 381 General Description......................................................................................................................................................... 381 Rear Suspension Construction............................................................................................................................................ 381 Rear Wheel Alignment Construction....................................................................................................................................... 383 Repair Instructions......................................................................................................................................................... 383 Rear Wheel Alignment Inspection and Adjustment.......................................................................................................................... 383 Rear Stabilizer Bar and/or Bushings Components.......................................................................................................................... 384 Rear Stabilizer Bar and/or Bushings Removal and Installation............................................................................................................ 385 Rear Stabilizer Bar, Bushing and/or Joint Check......................................................................................................................... 385 Rear Strut Assembly Components.......................................................................................................................................... 386 Rear Strut Assembly Removal and Installation............................................................................................................................ 387 Rear Strut Assembly Disassembly and Assembly............................................................................................................................ 388 Rear Strut Assembly Check............................................................................................................................................... 390 Control Rod Components.................................................................................................................................................. 390 Control Rod Removal and Installation.................................................................................................................................... 391 Control Rod Check....................................................................................................................................................... 392 Trailing Rod Removal and Installation................................................................................................................................... 392 Trailing Rod Check...................................................................................................................................................... 393 Rear Suspension Frame Components........................................................................................................................................ 393 Rear Suspension Frame Removal and Installation (2WD Model).............................................................................................................. 394 Rear Suspension Frame Removal and Installation (4WD Model).............................................................................................................. 396 Rear Suspension Frame, Bushing and Pad Check............................................................................................................................ 397 Wheel Hub with Wheel Bearing and Wheel Stud Removal and Installation (2WD Model)........................................................................................ 397 Wheel Hub, Wheel Stud / Wheel Bearing Outside Inner Race Removal and Installation (4WD Model)........................................................................... 398 Rear Wheel Hub, Wheel Bearing and Wheel Stud Inspection................................................................................................................. 400 Rear Wheel Disc, Nut and Bearing Check.................................................................................................................................. 400 Rear Knuckle Removal and Installation (2WD Model)....................................................................................................................... 400 Rear Knuckle, Wheel Bearing / Oil Seal Removal and Installation (4WD Model)............................................................................................. 402 Rear Suspension Knuckle Check........................................................................................................................................... 404 Rear Suspension Fasteners Check......................................................................................................................................... 404 Specifications.............................................................................................................................................................. 404 Tightening Torque Specifications........................................................................................................................................ 404 Special Tools and Equipment................................................................................................................................................. 405 Recommended Service Material............................................................................................................................................ 405 Special Tool............................................................................................................................................................ 405 Wheels and Tires................................................................................................................................................................ 407 General Description......................................................................................................................................................... 407 Tires Description....................................................................................................................................................... 407 Wheels Description...................................................................................................................................................... 408 Irregular and/or Premature Wear Description............................................................................................................................. 409 Wear Indicators Description............................................................................................................................................. 409 Radial Tire Waddle Description.......................................................................................................................................... 410 Radial Tire Lead / Pull Description..................................................................................................................................... 411 Balancing Wheels Description............................................................................................................................................ 411 Repair Instructions......................................................................................................................................................... 412 General Balance Procedures.............................................................................................................................................. 412 Tire Rotation........................................................................................................................................................... 412 Wheel Removal and Installation.......................................................................................................................................... 413 Tire Mounting and Dismounting........................................................................................................................................... 413 Tire Repair............................................................................................................................................................. 413 Specifications.............................................................................................................................................................. 414 Wheels and Tires Specifications......................................................................................................................................... 414 Tightening Torque Specifications........................................................................................................................................ 414 Driveline / Axle.................................................................................................................................................................... 415 Drive Shaft / Axle.............................................................................................................................................................. 416 General Description......................................................................................................................................................... 416 Front Drive Shaft Construction.......................................................................................................................................... 416 Diagnostic Information and Procedures....................................................................................................................................... 416 Front Drive Shaft Symptom Diagnosis..................................................................................................................................... 416 Repair Instructions......................................................................................................................................................... 417 Front Drive Shaft Components............................................................................................................................................ 417 Drive Shaft Boot On-Vehicle Inspection.................................................................................................................................. 418 Front Drive Shaft Assembly Removal and Installation..................................................................................................................... 418 Front Drive Shaft Disassembly and Assembly.............................................................................................................................. 420 Specifications.............................................................................................................................................................. 429 Tightening Torque Specifications........................................................................................................................................ 429 Special Tools and Equipment................................................................................................................................................. 429 Recommended Service Material............................................................................................................................................ 429 Special Tool............................................................................................................................................................ 429 Brakes.............................................................................................................................................................................. 431 Brake Control System and Diagnosis.............................................................................................................................................. 433 Precautions................................................................................................................................................................. 433 Precautions on Brake.................................................................................................................................................... 433 General Description......................................................................................................................................................... 434 Brakes Construction..................................................................................................................................................... 434 Front Brake Hose / Pipe Construction.................................................................................................................................... 435 Rear Brake Hose / Pipe Construction..................................................................................................................................... 438 Diagnostic Information and Procedures....................................................................................................................................... 439 Brakes Diagnosis Note................................................................................................................................................... 439 Brakes Symptom Diagnosis................................................................................................................................................ 439 Fluid Pressure Test (If Equipped with LSPV)............................................................................................................................. 442 Repair Instructions......................................................................................................................................................... 443 Brake Pedal Free Height Inspection...................................................................................................................................... 443 Brake Pedal Play Inspection............................................................................................................................................. 444 Excessive Pedal Travel Inspection....................................................................................................................................... 444 Master Cylinder and Brake Fluid Level Inspection........................................................................................................................ 445 Stop Light Switch Adjustment............................................................................................................................................ 445 Air Bleeding of Brake System............................................................................................................................................ 445 Front Brake Hose / Pipe Removal and Installation........................................................................................................................ 447 Rear Brake Hose / Pipe Removal and Installation......................................................................................................................... 447 Brake Hose and Pipe Inspection.......................................................................................................................................... 447 Master Cylinder Components.............................................................................................................................................. 448 Master Cylinder Reservoir Removal and Installation...................................................................................................................... 449 Master Cylinder Assembly Removal and Installation....................................................................................................................... 449 Master Cylinder Assembly Disassembly and Assembly....................................................................................................................... 450 Master Cylinder Assembly Inspection..................................................................................................................................... 452 Brake Booster Components................................................................................................................................................ 452 Booster Operation Inspection............................................................................................................................................ 453 Brake Booster Removal and Installation.................................................................................................................................. 454 Brake Booster Inspection and Adjustment................................................................................................................................. 455 LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped).......................................................................................................... 456 LSPV (Load Sensing Proportioning Valve) Removal and Installation........................................................................................................ 456 LSPV (Load Sensing Proportioning Valve) Inspection and Adjustment....................................................................................................... 457 Specifications.............................................................................................................................................................. 458 Tightening Torque Specifications........................................................................................................................................ 458 Special Tools and Equipment................................................................................................................................................. 459 Recommended Service Material............................................................................................................................................ 459 Special Tool............................................................................................................................................................ 459 Front Brakes.................................................................................................................................................................... 460 Repair Instructions......................................................................................................................................................... 460 Front Disc Brake Components............................................................................................................................................. 460 Front Disc Brake Pad On-Vehicle Inspection.............................................................................................................................. 461 Front Disc Brake Pad Removal and Installation........................................................................................................................... 461 Front Disc Brake Pad Inspection......................................................................................................................................... 462 Front Disc Brake Caliper Removal and Installation....................................................................................................................... 462 Front Disc Brake Caliper Disassembly and Assembly....................................................................................................................... 464 Front Disc Brake Caliper Inspection..................................................................................................................................... 466 Front Brake Disc Removal and Installation............................................................................................................................... 466 Front Brake Disc Inspection............................................................................................................................................. 467 Specifications.............................................................................................................................................................. 468 Tightening Torque Specifications........................................................................................................................................ 468 Special Tools and Equipment................................................................................................................................................. 468 Recommended Service Material............................................................................................................................................ 468 Special Tool............................................................................................................................................................ 468 Rear Brakes..................................................................................................................................................................... 469 Repair Instructions......................................................................................................................................................... 469 Rear Drum Brake Components.............................................................................................................................................. 469 Rear Brake Drum Removal and Installation................................................................................................................................ 469 Rear Brake Drum Inspection.............................................................................................................................................. 471 Rear Brake Shoe Removal and Installation................................................................................................................................ 472 Rear Brake Shoe Inspection.............................................................................................................................................. 473 Wheel Cylinder Removal and Installation................................................................................................................................. 473 Wheel Cylinder Inspection............................................................................................................................................... 474 Brake Back Plate Removal and Installation............................................................................................................................... 474 Specifications.............................................................................................................................................................. 475 Tightening Torque Specifications........................................................................................................................................ 475 Special Tools and Equipment................................................................................................................................................. 475 Recommended Service Material............................................................................................................................................ 475 Parking Brake................................................................................................................................................................... 476 General Description......................................................................................................................................................... 476 Parking Brake Cable Construction........................................................................................................................................ 476 Repair Instructions......................................................................................................................................................... 477 Parking Brake Inspection and Adjustment................................................................................................................................. 477 Parking Brake Cable Removal and Installation............................................................................................................................ 478 Specifications.............................................................................................................................................................. 478 Tightening Torque Specifications........................................................................................................................................ 478 ABS............................................................................................................................................................................. 479 Precautions................................................................................................................................................................. 479 Precautions in Diagnosing Troubles...................................................................................................................................... 479 Precautions in On-Vehicle Service....................................................................................................................................... 479 General Description......................................................................................................................................................... 480 ABS Construction........................................................................................................................................................ 480 ABS Hydraulic Unit / Control Module Assembly Description................................................................................................................ 480 Schematic and Routing Diagram............................................................................................................................................... 482 ABS Schematic........................................................................................................................................................... 482 ABS Wiring Circuit Diagram.............................................................................................................................................. 483 Component Location.......................................................................................................................................................... 485 ABS Components Location................................................................................................................................................. 485 Front Wheel Speed Sensor Components Location............................................................................................................................ 486 Rear Wheel Speed Sensor Components Location............................................................................................................................. 486 Diagnostic Information and Procedures....................................................................................................................................... 487 ABS Check............................................................................................................................................................... 487 ABS Warning Lamp Check.................................................................................................................................................. 489 EBD Warning Lamp (Brake Warning Lamp) Check............................................................................................................................. 489 DTC Check............................................................................................................................................................... 490 DTC Table............................................................................................................................................................... 491 DTC Clearance........................................................................................................................................................... 492 Scan Tool Data.......................................................................................................................................................... 493 ABS Warning Lamp Does Not Come ON at Ignition Switch ON................................................................................................................. 494 ABS Warning Lamp Comes ON Steady........................................................................................................................................ 495 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON....................................................................................................... 497 Code (DTC) Is Not Outputted Even with Diagnosis Switch Terminal Connected to Ground..................................................................................... 498 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady................................................................................................................... 499 Serial Data Link Circuit Check.......................................................................................................................................... 500 DTC C1015 (No. 15): G Sensor Circuit.................................................................................................................................... 502 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........................ 503 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.... 505 DTC C1057 (No. 57): Power Source Circuit................................................................................................................................ 506 DTC C1061 (No. 61): ABS Pump Motor and/or Motor Relay Circuit........................................................................................................... 508 DTC C1063 (No. 63): ABS Fail-Safe Relay Circuit......................................................................................................................... 509 DTC C1071 (No. 71): ABS Control Module.................................................................................................................................. 510 Repair Instructions......................................................................................................................................................... 511 ABS Hydraulic Unit Operation Check...................................................................................................................................... 511 ABS Hydraulic Unit / Control Module Assembly Components................................................................................................................. 513 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...................................................................................................... 513 ABS Hydraulic Unit / Control Module Assembly Removal and Installation................................................................................................... 513 Front Wheel Speed Sensor On-Vehicle Inspection.......................................................................................................................... 515 Front Wheel Speed Sensor Removal and Installation....................................................................................................................... 516 Front Wheel Speed Sensor Inspection..................................................................................................................................... 517 Rear Wheel Speed Sensor On-Vehicle Inspection........................................................................................................................... 517 Rear Wheel Speed Sensor Removal and Installation........................................................................................................................ 518 Rear Wheel Speed Sensor Inspection...................................................................................................................................... 520 Front Wheel Speed Sensor Ring On-Vehicle Inspection..................................................................................................................... 520 Front Wheel Speed Sensor Ring Removal and Installation.................................................................................................................. 520 Rear Wheel Speed Sensor Ring On-Vehicle Inspection...................................................................................................................... 520 Rear Wheel Speed Sensor Ring Removal and Installation................................................................................................................... 521 Specifications.............................................................................................................................................................. 521 Tightening Torque Specifications........................................................................................................................................ 521 Special Tools and Equipment................................................................................................................................................. 521 Special Tool............................................................................................................................................................ 521 Transmission / Transaxle............................................................................................................................................................ 523 Precautions..................................................................................................................................................................... 526 Precautions................................................................................................................................................................. 526 Precautions on Transmission / Transaxle................................................................................................................................. 526 Automatic Transmission/Transaxle................................................................................................................................................ 527 Precautions................................................................................................................................................................. 527 Precautions in Diagnosing Trouble....................................................................................................................................... 527 Precautions for Disassembly and Reassembly.............................................................................................................................. 527 General Description......................................................................................................................................................... 529 A/T Description......................................................................................................................................................... 529 Clutch / Brake / Planetary Gear Function of Automatic Transaxle......................................................................................................... 531 Table of Component Operation............................................................................................................................................ 532 A/T Diagnosis General Description....................................................................................................................................... 533 On-Board Diagnostic System Description.................................................................................................................................. 533 Schematic and Routing Diagram............................................................................................................................................... 535 Transmission Control Module (TCM) Wiring Diagram........................................................................................................................ 535 Automatic Gear Shift Table.............................................................................................................................................. 536 Component Location.......................................................................................................................................................... 537 Electronic Shift Control System Components Location..................................................................................................................... 537 Diagnostic Information and Procedures....................................................................................................................................... 538 A/T System Check........................................................................................................................................................ 538 Visual Inspection....................................................................................................................................................... 540 Malfunction Indicator Lamp (MIL) Check.................................................................................................................................. 541 “O/D OFF” Lamp Check.................................................................................................................................................... 541 DTC Table............................................................................................................................................................... 541 DTC Check............................................................................................................................................................... 543 DTC Clearance........................................................................................................................................................... 544 Fail Safe Table......................................................................................................................................................... 545 Scan Tool Data.......................................................................................................................................................... 546 A/T Basic Check......................................................................................................................................................... 548 Road Test............................................................................................................................................................... 549 Manual Road Test........................................................................................................................................................ 550 Stall Test.............................................................................................................................................................. 551 Time Lag Test........................................................................................................................................................... 552 Line Pressure Test...................................................................................................................................................... 553 Engine Brake Test....................................................................................................................................................... 554 “P” Range Test.......................................................................................................................................................... 554 A/T Symptom Diagnosis................................................................................................................................................... 555 No Gear Shift to O/D.................................................................................................................................................... 561 No Lock-Up Occurs....................................................................................................................................................... 562 DTC P0705 (No.34): Transmission Range Sensor Circuit Malfunction (PRNDL Input).......................................................................................... 562 DTC P0710 (No.36 / No.38): Transmission Fluid Temperature Sensor Circuit Malfunction.................................................................................... 564 DTC P0715 (No.37): Input / Turbine Speed Sensor Circuit Malfunction..................................................................................................... 566 DTC P0720 (No.31): Output Shaft Speed Sensor Circuit Malfunction........................................................................................................ 568 DTC P0725 (No.35): Engine Speed Input Circuit Malfunction............................................................................................................... 569 DTC P0741 (No.28): Torque Converter Clutch Circuit Performance or Stuck OFF............................................................................................. 571 DTC P0743 (No.25 / No.26): Torque Converter Clutch Circuit Electrical................................................................................................... 572 DTC P0748 (No.41 / No.42): Pressure Control Solenoid-A Electrical....................................................................................................... 574 DTC P0751 / P0756 (No.17 / No.28): Shift Solenoid-A (No.1) / -B (No.2) Performance or Stuck OFF......................................................................... 576 DTC P0753 / P0758 (No.21 / No.22 / No.23 / No.24): Shift Solenoid-A (No.1) Electrical / Shift Solenoid- B (No.2) Electrical............................................. 577 DTC P1700 (No.32 / No.33): Throttle Position Signal Input Malfunction................................................................................................... 579 DTC P1702 (No.52): Internal Malfunction of TCM.......................................................................................................................... 580 DTC P1705 (No.51): Engine Coolant Temperature Signal Circuit Malfunction................................................................................................ 581 DTC P1730 (No.64): Engine Torque Signal Circuit Malfunction............................................................................................................. 583 DTC P1895 (No.27): Torque Control Signal Malfunction.................................................................................................................... 584 Inspection of TCM and Its Circuits...................................................................................................................................... 586 TCM Power and Ground Circuit Check...................................................................................................................................... 588 “O/D OFF” Lamp Circuit Check............................................................................................................................................ 589 Repair Instructions......................................................................................................................................................... 592 A/T Fluid Level Check................................................................................................................................................... 592 A/T Fluid Change........................................................................................................................................................ 593 Select Cable Removal and Installation................................................................................................................................... 593 Selector Lever Components............................................................................................................................................... 594 Selector Lever Inspection............................................................................................................................................... 594 Select Cable Components................................................................................................................................................. 595 Selector Cable Adjustment............................................................................................................................................... 595 Transmission Range Sensor (Shift Switch) Inspection and Adjustment...................................................................................................... 596 Output Shaft Speed Sensor Removal and Installation...................................................................................................................... 597 Output Shaft Speed Sensor Inspection.................................................................................................................................... 597 Input Shaft Speed Sensor Removal and Installation....................................................................................................................... 597 Input Shaft Speed Sensor Inspection..................................................................................................................................... 598 Transmission Fluid Temperature Sensor Inspection........................................................................................................................ 598 “O/D OFF” Switch Inspection............................................................................................................................................. 599 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Pressure Control Solenoid Valve) Removal and Installation................................................ 599 Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve) Inspection............................................................................................... 601 Pressure Control Solenoid Valve Inspection.............................................................................................................................. 603 Transmission Control Module (TCM) Removal and Installation.............................................................................................................. 604 Differential Side Oil Seal Replacement.................................................................................................................................. 604 A/T Fluid Cooler Hoses Replacement...................................................................................................................................... 604 Automatic Transaxle Unit Components..................................................................................................................................... 605 Automatic Transaxle Unit Dismounting and Remounting..................................................................................................................... 605 Automatic Transaxle Assembly Components................................................................................................................................. 607 Automatic Transaxle Unit Disassembly.................................................................................................................................... 608 Oil Pump Components..................................................................................................................................................... 615 Oil Pump Disassembly and Reassembly..................................................................................................................................... 616 Oil Pump Inspection..................................................................................................................................................... 617 Forward Clutch Components............................................................................................................................................... 618 Forward Clutch Preliminary Check........................................................................................................................................ 618 Forward Clutch Disassembly and Reassembly............................................................................................................................... 619 Forward Clutch Inspection............................................................................................................................................... 621 Overdrive Clutch and Coast Clutch Components............................................................................................................................ 622 Overdrive Clutch and Coast Clutch Preliminary Check..................................................................................................................... 623 Overdrive Clutch and Coast Clutch Disassembly and Reassembly............................................................................................................ 624 Overdrive Clutch and Coast Clutch Inspection............................................................................................................................ 627 Planetary Gear Components............................................................................................................................................... 628 Planetary Gear Operation Check.......................................................................................................................................... 629 Planetary Gear Disassembly and Reassembly............................................................................................................................... 629 Planetary Gear Inspection............................................................................................................................................... 633 Reverse Clutch Components............................................................................................................................................... 633 Reverse Clutch Preliminary Inspection................................................................................................................................... 634 Reverse Clutch Disassembly and Reassembly............................................................................................................................... 635 Reverse Clutch Inspection............................................................................................................................................... 637 Counter Drive Gear Components........................................................................................................................................... 638 Counter Drive Gear Disassembly and Reassembly........................................................................................................................... 638 Counter Driven Gear Components.......................................................................................................................................... 640 Counter Driven Gear Disassembly and Reassembly.......................................................................................................................... 641 Valve Body Assembly Components.......................................................................................................................................... 643 Valve Body Assembly Disassembly and Reassembly.......................................................................................................................... 644 Differential Components................................................................................................................................................. 644 Differential Removal and Installation................................................................................................................................... 645 Differential Inspection................................................................................................................................................. 646 Transaxle housing Removal and Installation.............................................................................................................................. 647 Transaxle Housing Inspection............................................................................................................................................ 648 Transaxle Case Removal and Installation................................................................................................................................. 648 Automatic Transaxle Unit Assembly....................................................................................................................................... 649 Specifications.............................................................................................................................................................. 658 Tightening Torque Specifications........................................................................................................................................ 658 Special Tools and Equipment................................................................................................................................................. 659 Recommended Service Material............................................................................................................................................ 659 Special Tool............................................................................................................................................................ 659 Manual Transmission/Transaxle................................................................................................................................................... 662 General Description......................................................................................................................................................... 662 Manual Transaxle Construction........................................................................................................................................... 662 Diagnostic Information and Procedures....................................................................................................................................... 667 Manual Transaxle Symptom Diagnosis...................................................................................................................................... 667 Repair Instructions......................................................................................................................................................... 668 Manual Transaxle Oil Change............................................................................................................................................. 668 Differential Side Oil Seal Replacement.................................................................................................................................. 669 Gear Shift Control Lever and Cable Components........................................................................................................................... 670 Gear Shift Control Lever and Cable Removal and Installation............................................................................................................. 671 Vehicle Speed Sensor (VSS) Removal and Installation..................................................................................................................... 671 Back Up Lamp Switch Removal and Installation............................................................................................................................ 672 Back Up Lamp Switch Inspection.......................................................................................................................................... 672 Manual Transaxle Unit Components........................................................................................................................................ 673 Manual Transaxle Unit Dismounting and Remounting........................................................................................................................ 674 Gear Shift and Select Shaft Components.................................................................................................................................. 675 Gear Shift and Select Shaft Removal and Installation.................................................................................................................... 676 Gear Shift and Select Shaft Disassembly and Assembly.................................................................................................................... 677 Manual Transaxle Assembly Components.................................................................................................................................... 678 Fifth Gear Disassembly and Assembly..................................................................................................................................... 679 Manual Transaxle Assembly Disassembly and Assembly...................................................................................................................... 682 Right Case Disassembly and Assembly..................................................................................................................................... 688 Left Case Disassembly and Assembly...................................................................................................................................... 689 Input Shaft and Countershaft Components................................................................................................................................. 689 Input Shaft Disassembly and Assembly.................................................................................................................................... 690 Countershaft Disassembly and Assembly................................................................................................................................... 692 Gear Shift Shaft Components............................................................................................................................................. 696 Gear Shift Shaft Disassembly and Assembly............................................................................................................................... 697 Differential Components................................................................................................................................................. 698 Differential Disassembly and Assembly................................................................................................................................... 699 Transfer Components..................................................................................................................................................... 701 Transfer Assembly Disassembly and Assembly.............................................................................................................................. 702 Pinion Shaft Disassembly and Assembly................................................................................................................................... 709 Output Shaft Disassembly and Assembly................................................................................................................................... 711 Transfer Assembly Inspection............................................................................................................................................ 712 Gear Tooth Surface Contact Inspection................................................................................................................................... 712 Specifications.............................................................................................................................................................. 714 Tightening Torque Specifications........................................................................................................................................ 714 Special Tools and Equipment................................................................................................................................................. 715 Recommended Service Material............................................................................................................................................ 715 Special Tool............................................................................................................................................................ 715 Clutch.......................................................................................................................................................................... 718 General Description......................................................................................................................................................... 718 Clutch Construction..................................................................................................................................................... 718 Diagnostic Information and Procedures....................................................................................................................................... 719 Clutch System Symptom Diagnosis......................................................................................................................................... 719 Repair Instructions......................................................................................................................................................... 720 Clutch Pedal Inspection................................................................................................................................................. 720 Clutch Fluid Inspection................................................................................................................................................. 721 Clutch Fluid Pipe and Hose Components................................................................................................................................... 721 Clutch Fluid Pipe and Hose Removal and Installation..................................................................................................................... 722 Clutch Fluid Pipe and Hose Inspection................................................................................................................................... 722 Clutch Master Cylinder Removal and Installation......................................................................................................................... 722 Clutch Master Cylinder Components....................................................................................................................................... 724 Clutch Master Cylinder Disassembly and Reassembly....................................................................................................................... 724 Clutch Master Cylinder Inspection....................................................................................................................................... 724 Clutch Operating Cylinder Removal and Installation...................................................................................................................... 725 Clutch Operating Cylinder Components.................................................................................................................................... 726 Clutch Operating Cylinder Disassembly and Reassembly.................................................................................................................... 726 Clutch Operating Cylinder Inspection.................................................................................................................................... 726 Clutch Cover, Clutch Disc, Flywheel and Clutch Release System Components................................................................................................ 727 Clutch Cover, Clutch Disc and Flywheel Removal and Installation......................................................................................................... 727 Clutch Cover, Clutch Disc and Flywheel Inspection....................................................................................................................... 729 Clutch Release System Removal and Installation.......................................................................................................................... 729 Clutch Release System Inspection........................................................................................................................................ 731 Specifications.............................................................................................................................................................. 731 Tightening Torque Specifications........................................................................................................................................ 731 Special Tools and Equipment................................................................................................................................................. 732 Recommended Service Material............................................................................................................................................ 732 Special Tool............................................................................................................................................................ 732 Steering............................................................................................................................................................................ 733 Precautions..................................................................................................................................................................... 734 Precautions................................................................................................................................................................. 734 Precautions on Steering................................................................................................................................................. 734 Steering General Diagnosis...................................................................................................................................................... 735 Precautions................................................................................................................................................................. 735 Precautions for Steering, Suspension, Wheels and Tires Diagnosis........................................................................................................ 735 Diagnostic Information and Procedures....................................................................................................................................... 735 Steering Symptom Diagnosis.............................................................................................................................................. 735 Steering Wheel and Column....................................................................................................................................................... 736 Precautions................................................................................................................................................................. 736 Service Precautions of Steering Wheel and Column........................................................................................................................ 736 General Description......................................................................................................................................................... 736 Steering Column Construction............................................................................................................................................ 736 Steering Wheel and Driver Air Bag (Inflator) Module Construction........................................................................................................ 736 Steering Wheel and Column Construction.................................................................................................................................. 737 Diagnostic Information and Procedures....................................................................................................................................... 738 Inspection and Repair Required after Accident........................................................................................................................... 738 Steering Wheel and Column Diagnosis..................................................................................................................................... 738 Checking Steering Column Assembly for Accident Damage................................................................................................................... 738 Repair Instructions......................................................................................................................................................... 739 Steering Wheel Removal and Installation................................................................................................................................. 739 Contact Coil and Combination Switch Assembly Removal and Installation................................................................................................... 741 Centering Contact Coil.................................................................................................................................................. 742 Contact Coil and Combination Switch Assembly Inspection................................................................................................................. 743 Steering Column Assembly Removal and Installation....................................................................................................................... 743 Steering Column Assembly Inspection..................................................................................................................................... 746 Steering Lock Assembly (Ignition Switch) Removal and Installation....................................................................................................... 746 Steering Lower Shaft Removal and Installation........................................................................................................................... 747 Specifications.............................................................................................................................................................. 748 Tightening Torque Specifications........................................................................................................................................ 748 Special Tools and Equipment................................................................................................................................................. 748 Special Tool............................................................................................................................................................ 748 Power Assisted Steering System.................................................................................................................................................. 749 Precautions................................................................................................................................................................. 749 P/S System Note......................................................................................................................................................... 749 General Description......................................................................................................................................................... 750 P/S System Description.................................................................................................................................................. 750 Diagnostic Information and Procedures....................................................................................................................................... 751 P/S System Symptom Diagnosis............................................................................................................................................ 751 Steering Wheel Play Check............................................................................................................................................... 752 Steering Force Check.................................................................................................................................................... 752 Idle Up System Check.................................................................................................................................................... 753 Hydraulic Pressure in P/S Circuit Check................................................................................................................................. 753 Repair Instructions......................................................................................................................................................... 755 P/S Fluid Level Check................................................................................................................................................... 755 P/S Fluid Leakage Check................................................................................................................................................. 756 Air Bleeding Procedure.................................................................................................................................................. 757 P/S Pump Drive Belt On-Vehicle Inspection............................................................................................................................... 757 P/S Pump Drive Belt Tension Adjustment.................................................................................................................................. 757 P/S Pump Drive Belt Removal and Installation............................................................................................................................ 758 P/S Pump Drive Belt Inspection.......................................................................................................................................... 758 Tie-Rod End Boot On-Vehicle Inspection.................................................................................................................................. 758 Tie-Rod End Removal and Installation.................................................................................................................................... 758 Tie-Rod End Ball Joint Inspection....................................................................................................................................... 759 P/S Gear Box Components................................................................................................................................................. 760 Steering Shaft Joint On-Vehicle Inspection.............................................................................................................................. 761 P/S Gear Box Removal and Installation................................................................................................................................... 761 Steering Rack Boot On-Vehicle Inspection................................................................................................................................ 763 Tie-Rod / Rack Boot Removal and Installation............................................................................................................................ 764 P/S Pump Components..................................................................................................................................................... 765 P/S Pump Removal and Installation....................................................................................................................................... 766 P/S Pump Disassembly and Assembly....................................................................................................................................... 766 P/S Pump Inspection..................................................................................................................................................... 769 Specifications.............................................................................................................................................................. 770 P/S System Specification and Service Data............................................................................................................................... 770 Tightening Torque Specifications........................................................................................................................................ 771 Special Tools and Equipment................................................................................................................................................. 771 Recommended Service Material............................................................................................................................................ 771 Special Tool............................................................................................................................................................ 771 HVAC................................................................................................................................................................................ 773 Precautions..................................................................................................................................................................... 776 Precautions................................................................................................................................................................. 776 Precautions on HVAC..................................................................................................................................................... 776 Heater and Ventilation.......................................................................................................................................................... 777 Precautions................................................................................................................................................................. 777 Precautions in Diagnosing Trouble....................................................................................................................................... 777 General Description......................................................................................................................................................... 777 Heater and Ventilation Construction..................................................................................................................................... 777 On-Board Diagnostic System Description.................................................................................................................................. 778 Schematic and Routing Diagram............................................................................................................................................... 779 Heater and Ventilation Wiring Circuit Diagram........................................................................................................................... 779 Diagnostic Information and Procedures....................................................................................................................................... 780 Heater and Ventilation Symptom Diagnosis................................................................................................................................ 780 DTC Check............................................................................................................................................................... 781 DTC Clearance........................................................................................................................................................... 782 DTC Table............................................................................................................................................................... 783 Fail-Safe Table......................................................................................................................................................... 785 Scan Tool Data.......................................................................................................................................................... 785 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or its Circuit Malfunction........................................................................ 786 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or its Circuit malfunction........................................................................... 786 DTC B1513 (No.13): Temperature Control Actuator and/or its Circuit malfunction.......................................................................................... 786 DTC B1514 (No.14): Air Flow Control Actuator and/or its Circuit malfunction............................................................................................. 786 DTC B1520 (No.20): Temperature Selector and/ or its Circuit malfunction................................................................................................. 786 DTC B1521 (No.21): Blower Speed Selector and/ or Its Circuit............................................................................................................ 786 DTC B1522 (No.22): Air Flow Selector and/or its Circuit Malfunction..................................................................................................... 786 Inspection of HVAC Control Module and its Circuit....................................................................................................................... 787 Repair Instructions......................................................................................................................................................... 789 Blower Unit Components.................................................................................................................................................. 789 Blower Unit Removal and Installation.................................................................................................................................... 789 HVAC Air Filter Removal and Installation (If Equipped).................................................................................................................. 790 HVAC Air Filter Inspection (If Equipped)................................................................................................................................ 790 Blower Motor Removal and Installation................................................................................................................................... 790 Blower Motor Inspection................................................................................................................................................. 790 Blower Motor Controller Removal and Installation........................................................................................................................ 791 Blower Motor Controller Inspection...................................................................................................................................... 791 Blower Motor Relay Inspection........................................................................................................................................... 792 Heater Unit Components.................................................................................................................................................. 792 Heater Unit Removal and Installation.................................................................................................................................... 793 HVAC Control Module Removal and Installation............................................................................................................................ 793 Air Intake Control Actuator Removal and Installation.................................................................................................................... 794 Air Intake Control Actuator Inspection.................................................................................................................................. 794 Temperature Control Actuator Removal and Installation................................................................................................................... 794 Temperature Control Actuator Inspection................................................................................................................................. 795 Air Flow Control Actuator Removal and Installation...................................................................................................................... 795 Air Flow Control Actuator Inspection.................................................................................................................................... 796 Actuator Linkage Inspection............................................................................................................................................. 797 Center Ventilation Louver Removal and Installation...................................................................................................................... 797 Side Ventilation Louver Removal and Installation........................................................................................................................ 797 Special Tools and Equipment................................................................................................................................................. 797 Special Tool............................................................................................................................................................ 797 Air Conditioning System......................................................................................................................................................... 798 Manual Type................................................................................................................................................................. 798 Precautions............................................................................................................................................................. 798 A/C System Caution.................................................................................................................................................. 798 Precaution for Charging............................................................................................................................................. 798 Precaution in Diagnosing Trouble.................................................................................................................................... 799 Precautions on Servicing A/C System................................................................................................................................. 799 General Description..................................................................................................................................................... 800 A/C Evaporator Inlet Air Temperature Sensor and A/C Evaporator Outlet Air Temperature Sensor Construction........................................................... 800 Refrigerant Type Construction....................................................................................................................................... 800 Sub-Cool System Description......................................................................................................................................... 801 On-Board Diagnostic System Description.............................................................................................................................. 801 Schematic and Routing Diagram........................................................................................................................................... 802 Major Components of A/C System...................................................................................................................................... 802 A/C System Wiring Diagram........................................................................................................................................... 803 Diagnostic Information and Procedures................................................................................................................................... 804 A/C System Symptom Diagnosis........................................................................................................................................ 804 Abnormal Noise Symptom Diagnosis of A/C System...................................................................................................................... 806 DTC Check........................................................................................................................................................... 807 DTC Clearance....................................................................................................................................................... 807 DTC Table........................................................................................................................................................... 807 Fail-Safe Table..................................................................................................................................................... 807 Scan Tool Data...................................................................................................................................................... 808 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................................... 809 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or Its Circuit malfunction....................................................................... 809 DTC B1513 (No.13): Temperature Control Actuator and/or Its Circuit malfunction...................................................................................... 809 DTC B1514 (No.14): Air Flow Control Actuator and/or Its Circuit malfunction......................................................................................... 809 DTC B1520 (No.20): Temperature Selector and/or Its Circuit malfunction.............................................................................................. 809 DTC B1521 (No.21): Blower Speed Selector and/or Its Circuit......................................................................................................... 809 DTC B1522 (No.22): Air Flow Selector and/or Its Circuit Malfunction................................................................................................. 809 Air Conditioning System Check....................................................................................................................................... 809 Visual Inspection................................................................................................................................................... 811 Inspection of HVAC Control Module and Its Circuit................................................................................................................... 811 A/C System Performance Inspection................................................................................................................................... 813 A/C System Inspection at ECM........................................................................................................................................ 816 Repair Instructions..................................................................................................................................................... 817 Quick Checking of Refrigerant Charge................................................................................................................................ 817 Operation Procedure for Refrigerant Charging........................................................................................................................ 818 Heater and Cooling Unit Components.................................................................................................................................. 823 Heater and Cooling Unit Removal and Installation.................................................................................................................... 824 Condenser Assembly Removal and Installation......................................................................................................................... 825 Condenser Assembly Inspection....................................................................................................................................... 825 Desiccant Removal and Installation.................................................................................................................................. 825 Condenser Cooling Fan Removal and Installation...................................................................................................................... 826 Condenser Cooling Fan Inspection.................................................................................................................................... 826 A/C Evaporator Removal and Installation............................................................................................................................. 827 A/C Evaporator Inspection........................................................................................................................................... 828 A/C Evaporator Inlet and Outlet Air Temperature Sensor Removal and Installation..................................................................................... 828 A/C Evaporator Inlet and Outlet Air Temperature Sensors Inspection.................................................................................................. 828 Expansion Valve Removal and Installation............................................................................................................................ 828 Expansion Valve Inspection.......................................................................................................................................... 828 A/C Refrigerant Pressure Switch Removal and Installation............................................................................................................ 829 A/C Refrigerant Pressure Switch Inspection.......................................................................................................................... 829 Compressor Relay and Condenser Cooling Fan Relay Inspection......................................................................................................... 830 Compressor Drive Belt Removal and Installation...................................................................................................................... 830 Compressor Drive Belt Inspection.................................................................................................................................... 830 Compressor Removal and Installation................................................................................................................................. 830 Compressor Inspection............................................................................................................................................... 831 Magnet Clutch Components............................................................................................................................................ 831 Magnet Clutch Removal and Installation.............................................................................................................................. 832 Specifications.......................................................................................................................................................... 834 Tightening Torque Specifications.................................................................................................................................... 834 Special Tools and Equipment............................................................................................................................................. 834 Recommended Service Material........................................................................................................................................ 834 Special Tool........................................................................................................................................................ 834 Automatic Type.............................................................................................................................................................. 835 Precautions............................................................................................................................................................. 835 Air Bag Warning..................................................................................................................................................... 835 A/C System Caution.................................................................................................................................................. 835 Precaution for Charging............................................................................................................................................. 835 Precautions in Diagnosing Trouble................................................................................................................................... 835 Precautions on Servicing A/C System................................................................................................................................. 835 General Description..................................................................................................................................................... 835 A/C System Introduction............................................................................................................................................. 835 Refrigerant Type Construction....................................................................................................................................... 836 Sub-Cool System Description......................................................................................................................................... 836 On-Board Diagnostic System Description.............................................................................................................................. 836 Schematic and Routing Diagram........................................................................................................................................... 837 Major Components of A/C System...................................................................................................................................... 837 A/C System Wiring Diagram........................................................................................................................................... 837 Diagnostic Information and Procedures................................................................................................................................... 838 A/C System Symptom Diagnosis........................................................................................................................................ 838 Abnormal Noise Symptom Diagnosis of A/C System...................................................................................................................... 841 DTC Check........................................................................................................................................................... 841 DTC Clearance....................................................................................................................................................... 842 DTC Table........................................................................................................................................................... 843 Fail-Safe Table..................................................................................................................................................... 845 Scan Tool Data...................................................................................................................................................... 845 Air Conditioning System Check....................................................................................................................................... 847 Visual Inspection................................................................................................................................................... 849 DTC B1501 (No.01): Outside Air Temperature Sensor and/or Its Circuit Malfunction.................................................................................... 849 DTC B1502 (No.02): Inside Air Temperature Sensor and/or Its Circuit Malfunction..................................................................................... 850 DTC B1503 (No.03): A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction............................................................................. 851 DTC B1504 (No.04): Sunload Sensor and/or Its Circuit Malfunction.................................................................................................... 852 DTC B1510 (No.10): Engine Coolant Temperature (ECT) Sensor and/or Its Circuit Malfunction........................................................................... 853 DTC B1511 (No.11): Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................................... 854 DTC B1512 (No.12): Air Flow Control Actuator (Position Sensor) and/or Its Circuit malfunction....................................................................... 856 DTC B1513 (No.13): Temperature Control Actuator and/or Its Circuit malfunction...................................................................................... 857 DTC B1514 (No.14): Air Flow Control Actuator and/or Its Circuit malfunction......................................................................................... 860 DTC B1520 (No.20): Temperature Selector and/or Its Circuit malfunction.............................................................................................. 862 DTC B1521 (No.21): Blower Speed Selector and/or Its Circuit......................................................................................................... 862 DTC B1522 (No.22): Air Flow Selector and/or Its Circuit Malfunction................................................................................................. 862 Inspection of HVAC Control Module and Its Circuit................................................................................................................... 862 A/C System Performance Inspection................................................................................................................................... 865 A/C System Inspection at ECM........................................................................................................................................ 865 Repair Instructions..................................................................................................................................................... 865 Quick Checking of Refrigerant Charge................................................................................................................................ 865 Operation Procedure for Refrigerant Charging........................................................................................................................ 865 Heater and Cooling Unit Components.................................................................................................................................. 865 Heater and Cooling Unit Removal and Installation.................................................................................................................... 866 Sunload Sensor Removal and Installation............................................................................................................................. 866 Sunload Sensor Inspection........................................................................................................................................... 866 Outside Air Temperature Sensor Removal and Installation............................................................................................................. 866 Outside Air Temperature Sensor Inspection........................................................................................................................... 866 Inside Air Temperature Sensor Removal and Installation.............................................................................................................. 867 Inside Air Temperature Sensor Inspection............................................................................................................................ 867 Condenser Assembly Removal and Installation......................................................................................................................... 867 Condenser Assembly Inspection....................................................................................................................................... 867 Desiccant Removal and Installation.................................................................................................................................. 867 Condenser Cooling Fan Removal and Installation...................................................................................................................... 867 Condenser Cooling Fan Inspection.................................................................................................................................... 868 A/C Evaporator Removal and Installation............................................................................................................................. 868 A/C Evaporator Inspection........................................................................................................................................... 868 A/C Evaporator Outlet Air Temperature Sensor Removal and Installation............................................................................................... 868 A/C Evaporator Outlet Air Temperature Sensor Inspection............................................................................................................. 868 Expansion Valve Removal and Installation............................................................................................................................ 868 Expansion Valve Inspection.......................................................................................................................................... 868 A/C Refrigerant Pressure Switch Removal and Installation............................................................................................................ 868 A/C Refrigerant Pressure Switch Inspection.......................................................................................................................... 868 Compressor Relay and Condenser Cooling Fan Relay Inspection......................................................................................................... 868 Compressor Drive Belt Removal and Installation...................................................................................................................... 868 Compressor Drive Belt Inspection.................................................................................................................................... 868 Compressor Removal and Installation................................................................................................................................. 868 Compressor Inspection............................................................................................................................................... 868 Magnet Clutch Components............................................................................................................................................ 868 Magnet Clutch Removal and Installation.............................................................................................................................. 868 Special Tools and Equipment............................................................................................................................................. 869 Special Tool........................................................................................................................................................ 869 Restraint........................................................................................................................................................................... 871 Precautions..................................................................................................................................................................... 873 Precautions................................................................................................................................................................. 873 Precautions on Restraint................................................................................................................................................ 873 Seat Belts...................................................................................................................................................................... 874 Precautions................................................................................................................................................................. 874 Precautions on Service and Diagnosis of Seat Belt....................................................................................................................... 874 General Description......................................................................................................................................................... 875 Seat Belt Construction.................................................................................................................................................. 875 Restraint System Specification.......................................................................................................................................... 876 Diagnostic Information and Procedures....................................................................................................................................... 876 Inspection and Repair Required after Accident........................................................................................................................... 876 Repair Instructions......................................................................................................................................................... 877 Front Seat Belt Components.............................................................................................................................................. 877 Front Seat Belt Removal and Installation................................................................................................................................ 878 Front Seat Belt Inspection.............................................................................................................................................. 878 Rear Seat Belt Removal and Installation................................................................................................................................. 880 Rear Seat Belt Inspection............................................................................................................................................... 881 Specifications.............................................................................................................................................................. 881 Tightening Torque Specifications........................................................................................................................................ 881 Air Bag System.................................................................................................................................................................. 882 Precautions................................................................................................................................................................. 882 Precautions on Service and Diagnosis of Air Bag System.................................................................................................................. 882 Precautions on Handling and Storage of Air Bag Components............................................................................................................... 883 Precautions on Disposal of Air Bag and Seat Belt Pretensioner........................................................................................................... 886 General Description......................................................................................................................................................... 887 Air Bag System Construction............................................................................................................................................. 887 Schematic and Routing Diagram............................................................................................................................................... 889 Air Bag System Wiring Diagram........................................................................................................................................... 889 Component Location.......................................................................................................................................................... 891 Air Bag System Components, Wiring and Connectors Location............................................................................................................... 891 Diagnostic Information and Procedures....................................................................................................................................... 892 Repairs and Inspections Required after an Accident...................................................................................................................... 892 Inspection of Intermittents and Poor Connections........................................................................................................................ 894 Air Bag Diagnostic System Check......................................................................................................................................... 895 Air Bag Diagnostic System Check Flow.................................................................................................................................... 895 DTCs Description........................................................................................................................................................ 897 DTC Table............................................................................................................................................................... 897 DTC Check............................................................................................................................................................... 900 DTC Clearance........................................................................................................................................................... 901 Scan Tool Data.......................................................................................................................................................... 902 Scan Tool Data Definition............................................................................................................................................... 902 “AIR BAG” Warning Lamp Comes ON Steady.................................................................................................................................. 902 “AIR BAG” Warning Lamp Does Not Come ON................................................................................................................................. 904 “AIR BAG” Warning Lamp Flashes.......................................................................................................................................... 907 “AIR BAG” Warning Lamp Cannot Indicate Flashing......................................................................................................................... 908 SDM Cannot Communicate through the Serial Data Circuit.................................................................................................................. 910 DTC B1015: Passenger Air Bag Initiator Circuit Resistance High.......................................................................................................... 912 DTC B1016: Passenger Air Bag Initiator Circuit Resistance Low........................................................................................................... 915 DTC B1018: Passenger Air Bag Initiator Circuit Short to Ground.......................................................................................................... 918 DTC B1019: Passenger Air Bag Initiator Circuit Short to Power Circuit................................................................................................... 921 DTC B1021: Driver Air Bag Initiator Circuit Resistance High............................................................................................................. 924 DTC B1022: Driver Air Bag Initiator Circuit Resistance Low.............................................................................................................. 928 DTC B1024: Driver Air Bag Initiator Circuit Short to Ground............................................................................................................. 932 DTC B1025: Driver Air Bag Initiator Circuit Short to Power Circuit...................................................................................................... 936 DTC B1031: Power Source Voltage High.................................................................................................................................... 939 DTC B1032: Power Source Voltage Low..................................................................................................................................... 941 DTC B1041 / B1045: Driver Pretensioner Initiator Circuit Resistance High................................................................................................ 943 DTC B1042 / B1046: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..................................................................................... 946 DTC B1043 / B1047: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.................................................................................... 949 DTC B1044 / B1048: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit............................................................................. 952 DTC B1051: Frontal Crash Detected (System Activation Command Outputted)................................................................................................. 955 DTC B1056 / B1057: Sideward Crash (Driver / Passenger Side) Detected (Side Air Bag System Activation Command Outputted)................................................. 955 DTC B1058: Frontal Crash Detected (Pretensioner Activation Command Outputted)........................................................................................... 956 DTC B1061: “AIR BAG” Warning Lamp Circuit Failure....................................................................................................................... 957 DTC B1063 / B1065: Side Sensor (Driver / Passenger Side) Circuit Short to Ground........................................................................................ 958 DTC B1064 / B1066: Side Sensor (Driver / Passenger Side) Circuit Short to Power Circuit or Open......................................................................... 960 DTC B1071: Internal SDM Fault........................................................................................................................................... 963 DTC B1072 / B1074: Internal Side Sensor (Driver / Passenger Side) Fault................................................................................................. 963 DTC B1073 / B1075 Side Sensor (Driver / Passenger Side) Correspondence Abnormality...................................................................................... 963 DTC B1081 / B1085: Side Air Bag (Driver / Passenger Side) Initiator Circuit Resistance High............................................................................. 968 DTC B1082 / B1086 Side Air Bag (Driver / Passenger Side) Initiator Circuit Resistance Low............................................................................... 972 DTC B1083 / B1087 Side Air Bag (Driver / Passenger Side) Initiator Circuit Short to Ground.............................................................................. 976 DTC B1084 / B1088: Side Air Bag (Driver / Passenger Side) Initiator Circuit Short to Power Circuit...................................................................... 980 Repair Instructions......................................................................................................................................................... 984 Disabling Air Bag System................................................................................................................................................ 984 Enabling Air Bag System................................................................................................................................................. 985 SDM Removal and Installation............................................................................................................................................ 986 SDM Inspection.......................................................................................................................................................... 987 Side Sensor Removal and Installation.................................................................................................................................... 988 Side Sensor Inspection.................................................................................................................................................. 989 Driver Air Bag (Inflator) Module Removal and Installation............................................................................................................... 989 Driver Air Bag (Inflator) Module Inspection............................................................................................................................. 990 Passenger Air Bag (Inflator) Module Removal and Installation............................................................................................................ 991 Passenger Air Bag (Inflator) Module Inspection.......................................................................................................................... 992 Side Air Bag (Inflator) Module Removal and Installation................................................................................................................. 993 Side Air Bag (Inflator) Inspection...................................................................................................................................... 994 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal........................................................................................................... 994 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal........................................................................................1004 Specifications..............................................................................................................................................................1005 Tightening Torque Specifications........................................................................................................................................1005 Special Tools and Equipment.................................................................................................................................................1005 Use of Special Tools....................................................................................................................................................1005 Special Tool............................................................................................................................................................1007 Body, Cab and Accessories...........................................................................................................................................................1009 Precautions.....................................................................................................................................................................1013 Precautions.................................................................................................................................................................1013 Precautions on Body, Cab and Accessories................................................................................................................................1013 Precautions for Body Service............................................................................................................................................1013 Fastener Caution for Body Service.......................................................................................................................................1013 Wiring Systems..................................................................................................................................................................1014 Precautions.................................................................................................................................................................1014 Cautions in Body Electrical System Servicing............................................................................................................................1014 Precautions for Wiring System...........................................................................................................................................1014 General Description.........................................................................................................................................................1015 Applicable model........................................................................................................................................................1015 Abbreviations...........................................................................................................................................................1016 Wire / Connector Color Symbols..........................................................................................................................................1016 Symbols and Marks.......................................................................................................................................................1017 How to Read Connector Layout Diagram....................................................................................................................................1019 How to Read Connector Codes and Terminal Nos............................................................................................................................1020 How to Read Ground Point................................................................................................................................................1022 How to Read Power Supply Diagram........................................................................................................................................1023 How to Read System Circuit Diagram......................................................................................................................................1023 Connector Layout Diagram....................................................................................................................................................1025 Connector Layout Diagram................................................................................................................................................1025 Engine Compartment for Connector Layout Diagram.........................................................................................................................1025 Instrument Panel for Connector Layout Diagram...........................................................................................................................1031 Door, Roof for Connector Layout Diagram.................................................................................................................................1037 Floor for Connector Layout Diagram......................................................................................................................................1039 Rear for Connector Layout Diagram.......................................................................................................................................1047 Ground Point................................................................................................................................................................1049 Ground (Earth) Point....................................................................................................................................................1049 Power Supply Diagram........................................................................................................................................................1051 Power Supply Diagram....................................................................................................................................................1051 Power Supply Diagram (5 Door Type 1~3, 4 Door Type 1~2).................................................................................................................1052 Power Supply Diagram (5 Door Type 4, 4 Door Type 3).....................................................................................................................1053 Fuses and the Protected Parts...........................................................................................................................................1054 Fuses in Main Fuse Box..................................................................................................................................................1054 Individual Circuit Fuse Box, Supplementary Fuse Box (No. 1), Supplementary Fuse Box (No. 2).............................................................................1054 System Circuit Diagram......................................................................................................................................................1056 System Circuit Diagram..................................................................................................................................................1056 A-1 Cranking System Circuit Diagram.....................................................................................................................................1057 A-2 Charging System Circuit Diagram.....................................................................................................................................1058 A-3 Ignition System Circuit Diagram.....................................................................................................................................1059 A-4 Cooling System Circuit Diagram......................................................................................................................................1060 A-5 Engine and A/C Control System Circuit Diagram.......................................................................................................................1061 A-6 4 A/T Control System Circuit Diagram................................................................................................................................1065 A-7 Immobilizer Control System Circuit Diagram..........................................................................................................................1067 B-1 Windshield Wiper and Washer Circuit Diagram.........................................................................................................................1068 B-2 Rear Wiper and Washer Circuit Diagram (Instrument Panel Switch Type)................................................................................................1069 B-2 Rear Wiper and Washer Circuit Diagram (Column Lever Switch Type)....................................................................................................1070 B-3 Rear Defogger Circuit Diagram (5 Door Type 1).......................................................................................................................1071 B-3 Rear Defogger Circuit Diagram (5 Door Type 2~4, 4 Door).............................................................................................................1072 B-4 Power Window Circuit Diagram........................................................................................................................................1073 B-5 Power Door Lock Circuit Diagram.....................................................................................................................................1075 B-6 Power Mirror Circuit Diagram........................................................................................................................................1077 B-7 Horn Circuit Diagram................................................................................................................................................1078 B-8 Seat Heater Circuit Diagram.........................................................................................................................................1079 C-1 Combination Meter Circuit Diagram (Meter) <5 Door Type 1~3, 4 Door Type 1~2>........................................................................................1080 C-1 Combination Meter Circuit Diagram (Meter) <5 Door Type 4, 4 Door Type 3>............................................................................................1081 C-2 Combination Meter Circuit Diagram (Indicator) <5 Door Type 1~3, 4 Door Type 1~2>....................................................................................1082 C-2 Combination Meter Circuit Diagram (Indicator) <5 Door Type 4, 4 Door Type 3>........................................................................................1083 C-3 Combination Meter Circuit Diagram (Warning Light) <5 Door Type 1~3, 4 Door Type 1~2>................................................................................1084 C-3 Combination Meter Circuit Diagram (Warning Light) <5 Door Type 4, 4 Door Type 3>....................................................................................1086 D-1 Headlight System Circuit Diagram....................................................................................................................................1088 D-2 Position, Tail and Licence Plate Light Circuit Diagram..............................................................................................................1089 D-3 Fog Light Circuit Diagram...........................................................................................................................................1090 D-4 Illumination Light Circuit Diagram..................................................................................................................................1091 D-5 Interior Light Circuit Diagram......................................................................................................................................1092 D-6 Turn Signal and Hazard Warning Light Circuit Diagram................................................................................................................1093 D-7 Brake Light Circuit Diagram.........................................................................................................................................1094 D-8 Back-Up Light Circuit Diagram.......................................................................................................................................1095 D-9 Headlight Beam Leveling System Circuit Diagram......................................................................................................................1096 D-10 Rear fog light Circuit Diagram <5 Door Type 1~3, 4 Door Type 1~2>..................................................................................................1097 D-10 Rear fog light Circuit Diagram <5 Door Type 4, 4 Door Type 3>......................................................................................................1098 E-1 Heater and Air Conditioner Circuit Diagram..........................................................................................................................1099 E-2 Auto A/C System Circuit Diagram.....................................................................................................................................1100 F-1 Air-Bag Control System Circuit Diagram..............................................................................................................................1102 F-2 Anti-Lock Brake System Circuit Diagram..............................................................................................................................1104 G-1 Radio / Cigar Lighter Circuit Diagram (5 Door Type 1)...............................................................................................................1106 G-1 Radio / Cigar Lighter Circuit Diagram (5 Door Type 2~4, 4 Door).....................................................................................................1107 G-2 Clock Circuit Diagram...............................................................................................................................................1109 List of Connector...........................................................................................................................................................1110 List of Connectors......................................................................................................................................................1110 C Connector.............................................................................................................................................................1110 E Connector.............................................................................................................................................................1111 G Connector.............................................................................................................................................................1112 J Connector.............................................................................................................................................................1114 K Connector.............................................................................................................................................................1115 L Connector.............................................................................................................................................................1115 M Connector.............................................................................................................................................................1117 O Connector (for 5 Door)................................................................................................................................................1117 Lighting Systems................................................................................................................................................................1118 Component Location..........................................................................................................................................................1118 Headlights, Turn Signal and Hazard Warning, Front and Rear Fog Light (If Equipped) System Location......................................................................1118 Interior Light System Location..........................................................................................................................................1119 Diagnostic Information and Procedures.......................................................................................................................................1119 Headlight Symptom Diagnosis.............................................................................................................................................1119 Turn Signal and Hazard Warning Light Symptom Diagnosis..................................................................................................................1120 Clearance, Tail and License Plate Light Symptom Diagnosis...............................................................................................................1120 Back-Up Light Symptom Diagnosis.........................................................................................................................................1120 Stop (Brake) Lamp Symptom Diagnosis.....................................................................................................................................1121 Front Fog Light (If Equipped) Symptom Diagnosis.........................................................................................................................1121 Interior Light Symptom Diagnosis........................................................................................................................................1121 Repair Instructions.........................................................................................................................................................1122 Headlight Housing Removal and Installation..............................................................................................................................1122 Headlight Bulb Replacement..............................................................................................................................................1122 Headlight Aiming Adjustment with Screen.................................................................................................................................1123 Headlight Switch (in Lighting Switch) Removal and Installation..........................................................................................................1124 Headlight Switch (in Lighting Switch) Inspection........................................................................................................................1124 Headlight Diode Removal and Installation................................................................................................................................1125 Headlight Diode Inspection..............................................................................................................................................1125 Headlight, Clearance Light, Front / Rear Fog Light Relays Inspection....................................................................................................1125 Hazard Switch Inspection................................................................................................................................................1126 Stop (Brake) Lamp Switch Inspection.....................................................................................................................................1126 Turn Signal Light Switch (in Lighting Switch) Removal and Installation..................................................................................................1126 Turn Signal Light Switch (in Lighting Switch) Inspection................................................................................................................1127 Turn Signal and Hazard Relay Inspection.................................................................................................................................1127 License Lamp Assembly (for Wagon Model) Removal and Installation........................................................................................................1128 Front Fog Light Assembly Removal and Installation.......................................................................................................................1128 Fog Light Bulb Replacement..............................................................................................................................................1128 Front Fog Light Switch Inspection.......................................................................................................................................1129 Instrumentation / Driver Info. / Horn...........................................................................................................................................1130 Schematic and Routing Diagram...............................................................................................................................................1130 Combination Meter Circuit Diagram.......................................................................................................................................1130 Component Location..........................................................................................................................................................1132 Audio System Component Location.........................................................................................................................................1132 Diagnostic Information and Procedures.......................................................................................................................................1132 Speedometer and VSS Symptom Diagnosis...................................................................................................................................1132 Fuel Meter Symptom Diagnosis............................................................................................................................................1132 Low Fuel Warning Light Symptom Diagnosis................................................................................................................................1133 Oil Pressure Warning Light Symptom Diagnosis............................................................................................................................1133 Brake and Parking Brake Warning Light Symptom Diagnosis.................................................................................................................1133 Seat Belt Warning Light (If Equipped) Symptom Diagnosis.................................................................................................................1133 Ignition Key Reminder and Light Reminder Warning Buzzer Symptom Diagnosis...............................................................................................1134 A/T Shift Position Indicator (A/T Vehicle Only) Symptom Diagnosis.......................................................................................................1134 O/D OFF Indicator Lamp (A/T Vehicle Only) Symptom Diagnosis.............................................................................................................1134 Cigarette Lighter (If Equipped) Symptom Diagnosis.......................................................................................................................1134 Horn Symptom Diagnosis..................................................................................................................................................1135 Information Display (If Equipped) Symptom Diagnosis.....................................................................................................................1135 Audio System (If Equipped) Symptom Diagnosis............................................................................................................................1136 Remote Audio Control Switch (If Equipped) Symptom Diagnosis.............................................................................................................1137 Repair Instructions.........................................................................................................................................................1138 Ignition Switch Removal and Installation................................................................................................................................1138 Ignition Switch Inspection..............................................................................................................................................1138 Combination Meter Removal and Installation..............................................................................................................................1138 Fuel Level Sensor Removal and Installation..............................................................................................................................1138 Fuel Level Sensor Inspection............................................................................................................................................1139 Oil Pressure Switch Removal and Installation............................................................................................................................1139 Oil Pressure Switch On-Vehicle Inspection...............................................................................................................................1140 VSS Removal and Installation............................................................................................................................................1140 VSS Inspection..........................................................................................................................................................1140 Engine Coolant Temperature (ECT) Sensor Inspection......................................................................................................................1140 Brake Fluid Level Switch Inspection.....................................................................................................................................1140 Parking Brake Switch Inspection.........................................................................................................................................1140 Door Switch (Front / Rear Door) Inspection..............................................................................................................................1141 Rearend Door Switch (for Wagon Model) Inspection........................................................................................................................1141 Trunk Lid Switch Inspection.............................................................................................................................................1141 Outside Air Temperature Sensor (If Equipped with Information Display) Removal and Installation..........................................................................1141 Outside Air Temperature Sensor (If Equipped with Information Display) Inspection........................................................................................1142 Instrument Panel Removal and Installation...............................................................................................................................1142 Information Display or Clock Removal and Installation...................................................................................................................1143 Radio Assembly Removal and Installation.................................................................................................................................1144 Front Speaker Removal and Installation..................................................................................................................................1144 Rear Speaker (for Sedan Model) Removal and Installation.................................................................................................................1144 Rear Speaker (for Wagon Model) Removal and Installation.................................................................................................................1145 Antenna Amplifier (for Sedan Model) Removal and Installation............................................................................................................1145 Antenna Amplifier (for Wagon Model) Removal and Installation............................................................................................................1146 Remote Audio Control Switch Inspection..................................................................................................................................1146 Specifications..............................................................................................................................................................1146 Tightening Torque Specifications........................................................................................................................................1146 Wipers / Washers................................................................................................................................................................1147 Diagnostic Information and Procedures.......................................................................................................................................1147 Front Wiper and Washer Symptom Diagnosis................................................................................................................................1147 Repair Instructions.........................................................................................................................................................1148 Wipers and Washers Components...........................................................................................................................................1148 Washer Tank and Washer Pump Removal and Installation....................................................................................................................1149 Washer Pump Inspection..................................................................................................................................................1149 Windshield Wiper Motor Inspection.......................................................................................................................................1149 Windshield Wiper and Washer Switch Removal and Installation.............................................................................................................1150 Windshield Wiper and Washer Switch Inspection...........................................................................................................................1150 Glass / Windows / Mirrors.......................................................................................................................................................1153 General Description.........................................................................................................................................................1153 Windshield Construction.................................................................................................................................................1153 Component Location..........................................................................................................................................................1154 Power Window Control System Location....................................................................................................................................1154 Diagnostic Information and Procedures.......................................................................................................................................1155 Rear Window Defogger Symptom Diagnosis..................................................................................................................................1155 Power Window Control System Symptom Diagnosis...........................................................................................................................1155 Power Door Mirror Control System (If Equipped) Symptom Diagnosis........................................................................................................1155 Repair Instructions.........................................................................................................................................................1156 Windshield Removal and Installation.....................................................................................................................................1156 Front Pillar Window Removal and Installation............................................................................................................................1159 Front Door Window Components............................................................................................................................................1160 Front Door Glass Removal and Installation...............................................................................................................................1161 Front Door Window Regulator Removal and Installation....................................................................................................................1162 Front Door Window Regulator Inspection..................................................................................................................................1162 Rear Door Window Components.............................................................................................................................................1163 Rear Door Glass Removal and Installation................................................................................................................................1164 Rear Door Window Regulator Removal and Installation.....................................................................................................................1165 Rear Door Window Regulator Inspection...................................................................................................................................1165 Quarter Window (for Wagon Model) Removal and Installation...............................................................................................................1166 Rearend Door Window (for Wagon Model) Components........................................................................................................................1166 Rearend Door Glass (for Wagon Model) Removal and Installation...........................................................................................................1167 Back Window (for Sedan Model) Components................................................................................................................................1167 Back Window (for Sedan Model) Removal and Installation..................................................................................................................1168 Rearend Door Window / Back Window Defogger Switch and Its Circuit Inspection............................................................................................1168 Rearend Door Window / Back Window Defogger Wire Inspection..............................................................................................................1169 Rearend Door Window / Back Window Defogger Wire Repair..................................................................................................................1171 Power Window Main Switch Inspection.....................................................................................................................................1171 Power Window Sub Switch Inspection......................................................................................................................................1172 Door Mirror Components..................................................................................................................................................1172 Door Mirror Removal and Installation....................................................................................................................................1173 Power Door Mirror Switch Inspection.....................................................................................................................................1173 Power Door Mirror Actuator Inspection...................................................................................................................................1174 Specifications..............................................................................................................................................................1174 Tightening Torque Specifications........................................................................................................................................1174 Special Tools and Equipment.................................................................................................................................................1174 Recommended Service Material............................................................................................................................................1174 Security and Locks..............................................................................................................................................................1175 General Description.........................................................................................................................................................1175 Key Coding Construction.................................................................................................................................................1175 Component Location..........................................................................................................................................................1175 Power Door Lock and Keyless Entry System (If Equipped) Component Location...............................................................................................1175 Diagnostic Information and Procedures.......................................................................................................................................1176 Power Door Lock System (If Equipped) Symptom Diagnosis..................................................................................................................1176 Power Door Lock System Operation Inspection.............................................................................................................................1176 Power Door Lock System Circuit Inspection...............................................................................................................................1176 Keyless Entry System (If Equipped) Symptom Diagnosis....................................................................................................................1178 Keyless Entry System Operation Inspection...............................................................................................................................1179 Keyless Entry System Circuit Inspection.................................................................................................................................1179 Repair Instructions.........................................................................................................................................................1181 Front Door Lock Assembly Components.....................................................................................................................................1181 Front Door Lock Assembly Removal and Installation.......................................................................................................................1182 Power Door Lock Switch (If Equipped) Inspection.........................................................................................................................1183 Door Key Cylinder Switch (Driver and Passenger Side) Inspection.........................................................................................................1183 Power Door Lock Actuator Inspection.....................................................................................................................................1184 Front Door Lock Assembly Inspection.....................................................................................................................................1185 Rear Door Lock Assembly Components......................................................................................................................................1185 Rear Door Lock Assembly Removal and Installation........................................................................................................................1186 Rear Door Lock Assembly Inspection......................................................................................................................................1186 Rearend Door Lock Assembly (for Wagon Model) Components.................................................................................................................1187 Rearend Door Lock Assembly (for Wagon Model) Removal and Installation...................................................................................................1188 Rearend Door Lock Assembly (for Wagon Model) Inspection.................................................................................................................1188 Trunk Lid Lock Assembly (for Sedan Model) Components....................................................................................................................1189 Trunk Lid Lock Assembly (for Sedan Model) Removal and Installation......................................................................................................1189 Trunk Lid Lock Assembly (for Sedan Model) Inspection....................................................................................................................1190 Replacement of Transmitter Battery......................................................................................................................................1190 Programming Transmitter Code............................................................................................................................................1190 Special Tools and Equipment.................................................................................................................................................1191 Recommended Service Material............................................................................................................................................1191 Seats...........................................................................................................................................................................1192 Repair Instructions.........................................................................................................................................................1192 Front Seat Components...................................................................................................................................................1192 Front Seat Removal and Installation.....................................................................................................................................1193 Rear Seat Components....................................................................................................................................................1193 Rear Seat Removal and Installation......................................................................................................................................1194 Specifications..............................................................................................................................................................1195 Tightening Torque Specifications........................................................................................................................................1195 Interior Trim...................................................................................................................................................................1196 Repair Instructions.........................................................................................................................................................1196 Floor Carpet Removal and Installation...................................................................................................................................1196 Head Lining Removal and Installation....................................................................................................................................1196 Console Box Components..................................................................................................................................................1198 Specifications..............................................................................................................................................................1198 Tightening Torque Specifications........................................................................................................................................1198 Hood / Fenders / Doors..........................................................................................................................................................1199 Repair Instructions.........................................................................................................................................................1199 Hood Removal and Installation...........................................................................................................................................1199 Hood Inspection and Adjustment..........................................................................................................................................1199 Front Fender Components.................................................................................................................................................1200 Front Fender Removal and Installation...................................................................................................................................1200 Front Door Assembly Components..........................................................................................................................................1201 Front Door Assembly Removal and Installation............................................................................................................................1201 Rear Door Assembly Components...........................................................................................................................................1203 Rear Door Assembly Removal and Installation.............................................................................................................................1203 Rearend Door Assembly (for Wagon Model) Components......................................................................................................................1204 Rearend Door Assembly (for Wagon Model) Removal and Installation........................................................................................................1205 Trunk Lid (for Sedan Model) Components..................................................................................................................................1206 Trunk Lid (for Sedan Model) Removal and Installation....................................................................................................................1207 Specifications..............................................................................................................................................................1209 Tightening Torque Specifications........................................................................................................................................1209 Special Tools and Equipment.................................................................................................................................................1209 Recommended Service Material............................................................................................................................................1209 Body Structure..................................................................................................................................................................1210 Repair Instructions.........................................................................................................................................................1210 Front Bumper and Rear Bumper Components.................................................................................................................................1210 Front and Rear Bumper Side Garnish Removal and Installation.............................................................................................................1211 Specifications..............................................................................................................................................................1212 Body Dimensions.........................................................................................................................................................1212 Paint / Coatings................................................................................................................................................................1221 Sedan.......................................................................................................................................................................1221 General Description.....................................................................................................................................................1221 Anti-Corrosion Treatment Construction...............................................................................................................................1221 Plastic Parts Finishing.............................................................................................................................................1221 Component Location......................................................................................................................................................1222 Sealant Application Areas...........................................................................................................................................1222 Under Coating Application Areas.....................................................................................................................................1224 Anti-Corrosion Compound Application Area............................................................................................................................1226 Wagon.......................................................................................................................................................................1227 General Description.....................................................................................................................................................1227 Anti-Corrosion Treatment Construction...............................................................................................................................1227 Plastic Parts Finishing.............................................................................................................................................1227 Component Location......................................................................................................................................................1228 Sealant Application Areas...........................................................................................................................................1228 Under Coating Application Areas.....................................................................................................................................1233 Anti-Corrosion Compound Application Area............................................................................................................................1234 Exterior Trim...................................................................................................................................................................1235 Repair Instructions.........................................................................................................................................................1235 Roof Molding Components.................................................................................................................................................1235 Splash Guard (If Equipped) Components...................................................................................................................................1236 Control Systems.....................................................................................................................................................................1237 Immobilizer Control System......................................................................................................................................................1238 Precautions.................................................................................................................................................................1238 Precautions in Diagnosing Troubles......................................................................................................................................1238 Precautions in Handling Immobilizer Control System......................................................................................................................1239 General Description.........................................................................................................................................................1240 Immobilizer Control System Introduction.................................................................................................................................1240 On-Board Diagnostic System Description (Self- diagnosis Function).......................................................................................................1241 Schematic and Routing Diagram...............................................................................................................................................1242 Immobilizer Control System Wiring Circuit Diagram.......................................................................................................................1242 Diagnostic Information and Procedures.......................................................................................................................................1243 Immobilizer Control System Check........................................................................................................................................1243 DTC Check...............................................................................................................................................................1243 DTC Table...............................................................................................................................................................1244 Immobilizer Indicator Lamp Does Not Light at Ignition Switch ON.........................................................................................................1245 Immobilizer Indicator Lamp Remains ON after Engine Starts...............................................................................................................1246 DTC Is Not Output from Immobilizer Control Module.......................................................................................................................1247 DTC 11 / 32: Transponder Code Not Matched...............................................................................................................................1248 DTC 31: Transponder Code Not Registered.................................................................................................................................1248 DTC 12: Fault in Immobilizer Control Module.............................................................................................................................1248 DTC 13: No Transponder Code Transmitted or Coil Antenna Opened/Shorted..................................................................................................1249 DTC 21 / 81 (P1623) / 84 (P1620): ECM/Immobilizer Control Module (ECU) Code Not Matched.................................................................................1250 DTC 82 (P1622): Fault in ECM............................................................................................................................................1250 DTC 22: Ignition Switch Circuit Open/Short..............................................................................................................................1250 DTC 23 / 83 (P1621): No ECM/Immobilizer Control Module Code Transmitted or DLC Circuit Opened/ Shorted..................................................................1251 Inspection of ECM, Immobilizer Control Module and Its Circuit...........................................................................................................1253 Repair Instructions.........................................................................................................................................................1254 Immobilizer Control Module Removal and Installation.....................................................................................................................1254 How to Register Ignition Key............................................................................................................................................1255 Procedure after Immobilizer Control Module Replacement..................................................................................................................1255 Procedure after ECM Replacement.........................................................................................................................................1255 Special Tools and Equipment.................................................................................................................................................1255 Special Tool............................................................................................................................................................1255 COPYRIGHT...........................................................................................................................................................................1256 BOOKCOVER_VOL1......................................................................................................................................................................1257 BOOKCOVER_VOL2......................................................................................................................................................................1258
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