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SUZUKI RS413 RS415 SWIFT SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
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SUZUKI RS413 RS415 SWIFT SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
FILE DETAILS:
SUZUKI RS413 RS415 SWIFT SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
Language : English
Pages : 1553
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI RS413 RS415 SWIFT SERVICE MANUAL VOL 1&2 – PDF DOWNLOAD
TOP...................................................................................................................................................................................................................................... 0 MANUAL LIST.............................................................................................................................................................................................................................. 0 IMPORTANT................................................................................................................................................................................................................................ 1 FOREWORD................................................................................................................................................................................................................................. 3 TABLE OF CONTENTS........................................................................................................................................................................................................................ 5 Precautions.............................................................................................................................................................................................................................. 7 Precautions.......................................................................................................................................................................................................................... 8 Precautions...................................................................................................................................................................................................................... 8 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System............................................................................................................................................. 8 General Precautions.......................................................................................................................................................................................................... 11 Warning for Wheel (with tire) Removal........................................................................................................................................................................................ 14 Precautions in Servicing Full-Time 4WD Vehicle............................................................................................................................................................................... 14 Precautions for Catalytic Converter.......................................................................................................................................................................................... 14 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 15 Precaution for CAN Communication System...................................................................................................................................................................................... 15 Precautions for Electrical Circuit Service................................................................................................................................................................................... 15 Air Bag Warning.............................................................................................................................................................................................................. 17 Air Bag System Service Warning............................................................................................................................................................................................... 17 Fastener Caution............................................................................................................................................................................................................. 18 Suspension Caution........................................................................................................................................................................................................... 18 Wheels and Tires Caution..................................................................................................................................................................................................... 18 Brake Caution................................................................................................................................................................................................................ 18 Repair Instructions.............................................................................................................................................................................................................. 19 Electrical Circuit Inspection Procedure...................................................................................................................................................................................... 19 Intermittent and Poor Connection Inspection.................................................................................................................................................................................. 21 General Information...................................................................................................................................................................................................................... 23 General Information.................................................................................................................................................................................................................. 24 General Description.............................................................................................................................................................................................................. 24 Abbreviations................................................................................................................................................................................................................ 24 Symbols...................................................................................................................................................................................................................... 25 Wire Color Symbols........................................................................................................................................................................................................... 26 Fasteners Information........................................................................................................................................................................................................ 26 Vehicle Lifting Points....................................................................................................................................................................................................... 28 Engine Supporting Points..................................................................................................................................................................................................... 30 Vehicle Identification Number................................................................................................................................................................................................ 30 Engine Identification Number................................................................................................................................................................................................. 30 Transmission Identification Number........................................................................................................................................................................................... 30 Component Location............................................................................................................................................................................................................... 31 Warning, Caution and Information Labels Location............................................................................................................................................................................. 31 Maintenance and Lubrication.......................................................................................................................................................................................................... 33 Precautions...................................................................................................................................................................................................................... 33 Precautions for Maintenance and Lubrication.................................................................................................................................................................................. 33 Scheduled Maintenance............................................................................................................................................................................................................ 33 Maintenance Schedule under Normal Driving Conditions......................................................................................................................................................................... 33 Maintenance Recommended under Severe Driving Conditions...................................................................................................................................................................... 34 Repair Instructions.............................................................................................................................................................................................................. 35 Accessory Drive Belt Inspection.............................................................................................................................................................................................. 35 Accessory Drive Belt Replacement............................................................................................................................................................................................. 36 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 36 Engine Oil and Filter Change................................................................................................................................................................................................. 36 Engine Coolant Change........................................................................................................................................................................................................ 38 Exhaust System Inspection.................................................................................................................................................................................................... 38 Spark Plug Replacement....................................................................................................................................................................................................... 38 Air Cleaner Filter Inspection................................................................................................................................................................................................ 38 Air Cleaner Filter Replacement............................................................................................................................................................................................... 38 Fuel Lines and Connections Inspection........................................................................................................................................................................................ 39 Fuel Filter Replacement...................................................................................................................................................................................................... 39 Fuel Tank Inspection......................................................................................................................................................................................................... 39 PCV Valve Inspection......................................................................................................................................................................................................... 39 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 39 Brake Discs and Pads (Front) Inspection...................................................................................................................................................................................... 39 Brake Drums and Shoes (Rear) Inspection...................................................................................................................................................................................... 40 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 40 Brake Fluid Replacement...................................................................................................................................................................................................... 40 Brake Lever and Cable Inspection............................................................................................................................................................................................. 40 Clutch Fluid Inspection...................................................................................................................................................................................................... 41 Tires Inspection............................................................................................................................................................................................................. 41 Wheel Discs Inspection....................................................................................................................................................................................................... 41 Wheel Bearing Inspection..................................................................................................................................................................................................... 41 Suspension System Inspection................................................................................................................................................................................................. 41 Steering System Inspection................................................................................................................................................................................................... 42 Drive Shaft (Axle) Boots Inspection.......................................................................................................................................................................................... 42 Propeller Shafts (4WD) Inspection............................................................................................................................................................................................ 42 Manual Transaxle Oil Inspection.............................................................................................................................................................................................. 43 Manual Transaxle Oil Replacement............................................................................................................................................................................................. 43 Automatic Transaxle Fluid Level Inspection................................................................................................................................................................................... 43 Automatic Transaxle Fluid Replacement........................................................................................................................................................................................ 43 Automatic Transaxle Fluid Cooler Hose Inspection............................................................................................................................................................................. 44 Transfer Oil (4WD) and Rear Differential Oil (4WD) Inspection................................................................................................................................................................ 44 Transfer Oil (4WD) and Rear Differential Oil (4WD) Replacement............................................................................................................................................................... 44 All Latches, Hinges and Locks Inspection..................................................................................................................................................................................... 44 HVAC Air Filter (If Equipped) Inspection..................................................................................................................................................................................... 45 HVAC Air Filter (If Equipped) Replacement.................................................................................................................................................................................... 45 Final Inspection for Maintenance Service..................................................................................................................................................................................... 45 Specifications................................................................................................................................................................................................................... 47 Tightening Torque Specifications............................................................................................................................................................................................. 47 Special Tools and Equipment...................................................................................................................................................................................................... 47 Recommended Fluids and Lubricants............................................................................................................................................................................................ 47 Special Tool................................................................................................................................................................................................................. 47 Engine................................................................................................................................................................................................................................... 49 Precautions.......................................................................................................................................................................................................................... 54 Precautions...................................................................................................................................................................................................................... 54 Precautions for Engine....................................................................................................................................................................................................... 54 Engine General Information and Diagnosis............................................................................................................................................................................................. 55 Precautions...................................................................................................................................................................................................................... 55 Precautions on Engine Service................................................................................................................................................................................................ 55 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 55 Precautions of ECM Circuit Inspection........................................................................................................................................................................................ 56 General Description.............................................................................................................................................................................................................. 56 Statement on Cleanliness and Care............................................................................................................................................................................................ 56 Engine Diagnosis General Description......................................................................................................................................................................................... 56 On-Board Diagnostic System Description....................................................................................................................................................................................... 56 Engine and Emission Control System Description............................................................................................................................................................................... 60 CAN Communication System Description......................................................................................................................................................................................... 60 Air Intake System Description................................................................................................................................................................................................ 62 Generator Control System Description (Vehicle Equipped with Electric Load Current Sensor).................................................................................................................................... 63 Electronic Control System Description........................................................................................................................................................................................ 64 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 70 Schematic and Routing Diagram.................................................................................................................................................................................................... 71 Engine and Emission Control System Diagram................................................................................................................................................................................... 71 Component Location............................................................................................................................................................................................................... 72 Electronic Control System Components Location................................................................................................................................................................................ 72 Diagnostic Information and Procedures............................................................................................................................................................................................ 73 Engine and Emission Control System Check..................................................................................................................................................................................... 73 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 76 DTC Check.................................................................................................................................................................................................................... 77 DTC Clearance................................................................................................................................................................................................................ 78 DTC Table.................................................................................................................................................................................................................... 78 Fail-Safe Table.............................................................................................................................................................................................................. 83 Scan Tool Data............................................................................................................................................................................................................... 84 Visual Inspection............................................................................................................................................................................................................ 88 Engine Basic Inspection...................................................................................................................................................................................................... 89 Engine Symptom Diagnosis..................................................................................................................................................................................................... 92 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started).............................................................................................................. 98 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 100 DTC P0010: Camshaft Position Actuator Circuit (For Engine with VVT).......................................................................................................................................................... 102 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For Engine with VVT).......................................................................................................... 104 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 106 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 108 DTC P0101: Mass Air Flow Circuit Range / Performance......................................................................................................................................................................... 110 DTC P0102: Mass Air Flow Circuit Low Input................................................................................................................................................................................... 114 DTC P0103: Mass Air Flow Circuit High Input.................................................................................................................................................................................. 116 DTC P0106: Manifold Absolute Pressure Range / Performance.................................................................................................................................................................... 118 DTC P0107: Manifold Absolute Pressure Circuit Low Input...................................................................................................................................................................... 120 DTC P0108: Manifold Absolute Pressure Circuit High Input..................................................................................................................................................................... 122 DTC P0111: Intake Air Temperature Circuit Range / Performance................................................................................................................................................................ 124 DTC P0112: Intake Air Temperature Sensor Circuit Low......................................................................................................................................................................... 128 DTC P0113: Intake Air Temperature Sensor Circuit High........................................................................................................................................................................ 130 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 133 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 136 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 138 DTC P0121: Throttle Position Sensor Circuit Range / Performance.............................................................................................................................................................. 140 DTC P0122: Throttle Position Sensor Circuit Low.............................................................................................................................................................................. 144 DTC P0123: Throttle Position Sensor Circuit High............................................................................................................................................................................. 147 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................................................................................................ 150 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 153 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).......................................................................................................................................................... 154 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 157 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 160 DTC P0171 / P0172: Fuel System Too Lean / Rich............................................................................................................................................................................... 162 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...................................................................................... 164 DTC P0327 / P0328: Knock Sensor Circuit Low / High........................................................................................................................................................................... 166 DTC P0335: Crankshaft Position (CKP) Sensor Circuit.......................................................................................................................................................................... 168 DTC P0340: Camshaft Position (CMP) Sensor Circuit............................................................................................................................................................................ 170 DTC P0350: Ignition Coil Primary / Secondary Circuit......................................................................................................................................................................... 173 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 175 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 178 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 180 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 182 DTC P0462: Fuel Level Sensor Circuit Low..................................................................................................................................................................................... 184 DTC P0463: Fuel Level Sensor Circuit High.................................................................................................................................................................................... 186 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 188 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction............................................................................................................................................................................ 192 DTC P0505: Idle Air Control System........................................................................................................................................................................................... 195 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low....................................................................................................................................................................... 198 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...................................................................................................................................................................... 200 DTC P0601 / P0602: Internal Control Module Memory Check Sum Error / Control Module Programming Error......................................................................................................................... 202 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 203 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 205 DTC P0620: Generator Control Circuit......................................................................................................................................................................................... 207 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High............................................................................................................................................................... 209 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High........................................................................................................................................................... 211 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 213 DTC P1603: TCM Trouble Code Detected......................................................................................................................................................................................... 214 DTC P1674: CAN Communication (Bus Off Error)................................................................................................................................................................................. 215 DTC P1675: CAN Communication (Transmission Error)............................................................................................................................................................................ 220 DTC P1676: CAN Communication (Reception Error for TCM)....................................................................................................................................................................... 224 DTC P1678: CAN Communication (Reception Error for BCM)....................................................................................................................................................................... 227 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 230 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 231 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 253 Fuel Injector Circuit Check.................................................................................................................................................................................................. 256 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 258 Fuel Pressure Check.......................................................................................................................................................................................................... 261 Idle Air Control System Check................................................................................................................................................................................................ 262 A/C System Circuits Check.................................................................................................................................................................................................... 264 Electric Load Signal Circuit Check........................................................................................................................................................................................... 268 Radiator Cooling Fan Low Speed Control System Check.......................................................................................................................................................................... 269 Radiator Cooling Fan High Speed Control System Check......................................................................................................................................................................... 271 Repair Instructions.............................................................................................................................................................................................................. 274 Idle Speed / Idle Air Control (IAC) Duty Inspection.......................................................................................................................................................................... 274 Special Tools and Equipment...................................................................................................................................................................................................... 275 Special Tool................................................................................................................................................................................................................. 275 Aux. Emission Control Devices........................................................................................................................................................................................................ 276 Diagnostic Information and Procedures............................................................................................................................................................................................ 276 EGR System Inspection........................................................................................................................................................................................................ 276 Repair Instructions.............................................................................................................................................................................................................. 276 EVAP Canister Purge Inspection............................................................................................................................................................................................... 276 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 277 Vacuum Passage Inspection.................................................................................................................................................................................................... 278 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................................................................................................... 278 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 278 EVAP Canister Inspection..................................................................................................................................................................................................... 279 EGR Valve Removal and Installation........................................................................................................................................................................................... 279 EGR Valve Inspection......................................................................................................................................................................................................... 279 PCV Hose Inspection.......................................................................................................................................................................................................... 280 PCV Valve Inspection......................................................................................................................................................................................................... 280 Special Tools and Equipment...................................................................................................................................................................................................... 280 Special Tool................................................................................................................................................................................................................. 280 Engine Electrical Devices............................................................................................................................................................................................................ 281 Repair Instructions.............................................................................................................................................................................................................. 281 Idle Air Control (IAC) Valve Operation Inspection............................................................................................................................................................................ 281 Idle Air Control (IAC) Valve On-Vehicle Inspection........................................................................................................................................................................... 281 Idle Air Control (IAC) Valve Removal and Installation........................................................................................................................................................................ 281 Engine Control Module (ECM) Removal and Installation......................................................................................................................................................................... 282 Manifold Absolute Pressure (MAP) Sensor Inspection........................................................................................................................................................................... 283 Throttle Position (TP) Sensor On-Vehicle Inspection.......................................................................................................................................................................... 283 Throttle Position (TP) Sensor Removal and Installation....................................................................................................................................................................... 283 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................................................................................................................. 284 Engine Coolant Temperature (ECT) Sensor Inspection........................................................................................................................................................................... 284 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection........................................................................................................................................................ 285 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation............................................................................................................................................................ 285 Camshaft Position (CMP) Sensor Removal and Installation...................................................................................................................................................................... 285 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 286 Crankshaft Position (CKP) Sensor Removal and Installation.................................................................................................................................................................... 287 Crankshaft Position (CKP) Sensor Inspection.................................................................................................................................................................................. 287 Vehicle Speed Sensor (VSS) Inspection (M/T model)............................................................................................................................................................................ 288 Knock Sensor Removal and Installation........................................................................................................................................................................................ 288 Main Relay, Fuel Pump Relay and Starting Motor Control Relay Inspection...................................................................................................................................................... 289 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................................................................................................ 289 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation......................................................................................................................................... 290 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection....................................................................................................................................................... 290 Electric Load Current Sensor On-Vehicle Inspection (If Equipped)............................................................................................................................................................. 291 Specifications................................................................................................................................................................................................................... 292 Tightening Torque Specifications............................................................................................................................................................................................. 292 Special Tools and Equipment...................................................................................................................................................................................................... 292 Special Tool................................................................................................................................................................................................................. 292 Engine Mechanical.................................................................................................................................................................................................................... 293 General Description.............................................................................................................................................................................................................. 293 Engine Construction Description.............................................................................................................................................................................................. 293 Camshaft Position Control (VVT Variable Valve Timing) System Description..................................................................................................................................................... 295 Diagnostic Information and Procedures............................................................................................................................................................................................ 297 Compression Check............................................................................................................................................................................................................ 297 Engine Vacuum Check.......................................................................................................................................................................................................... 298 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 299 Repair Instructions.............................................................................................................................................................................................................. 302 Air Cleaner Filter Removal and Installation.................................................................................................................................................................................. 302 Air Cleaner Filter Inspection and Cleaning................................................................................................................................................................................... 302 Cylinder Head Cover Removal and Installation................................................................................................................................................................................. 302 Accelerator Cable Adjustment................................................................................................................................................................................................. 304 Throttle Body and Intake Manifold Components................................................................................................................................................................................. 305 Throttle Body On-Vehicle Inspection.......................................................................................................................................................................................... 306 Throttle Body Removal and Installation....................................................................................................................................................................................... 306 Throttle Body Cleaning....................................................................................................................................................................................................... 307 Intake Manifold Removal and Installation..................................................................................................................................................................................... 307 Engine Mountings Components.................................................................................................................................................................................................. 308 Engine Assembly Removal and Installation..................................................................................................................................................................................... 309 Timing Chain Cover Components................................................................................................................................................................................................ 313 Timing Chain Cover Removal and Installation.................................................................................................................................................................................. 314 Timing Chain Cover Inspection................................................................................................................................................................................................ 316 Oil Control Valve Removal and Installation (For Engine with VVT)............................................................................................................................................................. 317 Oil Control Valve Inspection (For Engine with VVT)........................................................................................................................................................................... 317 Timing Chain and Chain Tensioner Components.................................................................................................................................................................................. 318 Timing Chain and Chain Tensioner Removal and Installation.................................................................................................................................................................... 318 Timing Chain and Chain Tensioner Inspection.................................................................................................................................................................................. 322 Camshaft, Tappet and Shim Components......................................................................................................................................................................................... 323 Camshaft, Tappet and Shim Removal and Installation........................................................................................................................................................................... 324 Camshaft, Tappet and Shim Inspection......................................................................................................................................................................................... 327 Valves and Cylinder Head Components.......................................................................................................................................................................................... 330 Valves and Cylinder Head Removal and Installation............................................................................................................................................................................ 331 Valves and Cylinder Head Disassembly and Assembly............................................................................................................................................................................ 333 Valves and Valve Guides Inspection........................................................................................................................................................................................... 336 Cylinder Head Inspection..................................................................................................................................................................................................... 338 Valve Spring Inspection...................................................................................................................................................................................................... 339 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................................................................................................. 340 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................................................................................................ 340 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................................................................................................ 342 Cylinders, Pistons and Piston Rings Inspection............................................................................................................................................................................... 343 Piston Pins and Connecting Rods Inspection................................................................................................................................................................................... 345 Crank Pin and Connecting Rod Bearings Inspection............................................................................................................................................................................. 346 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................................................................................................... 349 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................................................................................................ 350 Crankshaft Inspection........................................................................................................................................................................................................ 353 Main Bearings Inspection..................................................................................................................................................................................................... 354 Sensor Plate Inspection...................................................................................................................................................................................................... 360 Rear Oil Seal Inspection..................................................................................................................................................................................................... 360 Flywheel Inspection.......................................................................................................................................................................................................... 361 Cylinder Block Inspection.................................................................................................................................................................................................... 361 Specifications................................................................................................................................................................................................................... 362 Tightening Torque Specifications............................................................................................................................................................................................. 362 Special Tools and Equipment...................................................................................................................................................................................................... 363 Recommended Service Material................................................................................................................................................................................................. 363 Special Tool................................................................................................................................................................................................................. 363 Engine Lubrication System............................................................................................................................................................................................................ 365 General Description.............................................................................................................................................................................................................. 365 Engine Lubrication Description............................................................................................................................................................................................... 365 Diagnostic Information and Procedures............................................................................................................................................................................................ 367 Oil Pressure Check........................................................................................................................................................................................................... 367 Repair Instructions.............................................................................................................................................................................................................. 368 Oil Pan and Oil Pump Strainer Components..................................................................................................................................................................................... 368 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................................................................................................... 369 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................................................................................................... 371 Oil Pump Components.......................................................................................................................................................................................................... 371 Oil Pump Removal and Installation............................................................................................................................................................................................ 371 Oil Pump Disassembly and Reassembly.......................................................................................................................................................................................... 371 Oil Pump Inspection.......................................................................................................................................................................................................... 372 Specifications................................................................................................................................................................................................................... 374 Tightening Torque Specifications............................................................................................................................................................................................. 374 Special Tools and Equipment...................................................................................................................................................................................................... 374 Recommended Service Material................................................................................................................................................................................................. 374 Special Tool................................................................................................................................................................................................................. 374 Engine Cooling System................................................................................................................................................................................................................ 375 General Description.............................................................................................................................................................................................................. 375 Cooling System Description................................................................................................................................................................................................... 375 Coolant Description.......................................................................................................................................................................................................... 375 Schematic and Routing Diagram.................................................................................................................................................................................................... 376 Coolant Circulation.......................................................................................................................................................................................................... 376 Diagnostic Information and Procedures............................................................................................................................................................................................ 377 Engine Cooling Symptom Diagnosis............................................................................................................................................................................................. 377 Repair Instructions.............................................................................................................................................................................................................. 378 Cooling System Components.................................................................................................................................................................................................... 378 Coolant Level Check.......................................................................................................................................................................................................... 379 Engine Cooling System Inspection and Cleaning................................................................................................................................................................................ 379 Cooling System Draining...................................................................................................................................................................................................... 379 Cooling System Flush and Refill.............................................................................................................................................................................................. 380 Cooling Water Pipes or Hoses Removal and Installation........................................................................................................................................................................ 381 Thermostat Removal and Installation.......................................................................................................................................................................................... 381 Thermostat Inspection........................................................................................................................................................................................................ 382 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................................................................................................................. 382 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 383 Radiator Cooling Fan Removal and Installation................................................................................................................................................................................ 383 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 383 Radiator Removal and Installation............................................................................................................................................................................................ 384 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.......................................................................................................................................................... 384 Water Pump / Generator Drive Belt Removal and Installation................................................................................................................................................................... 385 Water Pump Removal and Installation.......................................................................................................................................................................................... 385 Water Pump Inspection........................................................................................................................................................................................................ 386 Specifications................................................................................................................................................................................................................... 386 Tightening Torque Specifications............................................................................................................................................................................................. 386 Special Tools and Equipment...................................................................................................................................................................................................... 386 Recommended Service Material................................................................................................................................................................................................. 386 Fuel System.......................................................................................................................................................................................................................... 387 Precautions...................................................................................................................................................................................................................... 387 Precautions on Fuel System Service........................................................................................................................................................................................... 387 General Description.............................................................................................................................................................................................................. 388 Fuel System Description...................................................................................................................................................................................................... 388 Fuel Delivery System Description............................................................................................................................................................................................. 388 Fuel Pump Description........................................................................................................................................................................................................ 388 Schematic and Routing Diagram.................................................................................................................................................................................................... 389 Fuel Delivery System Diagram................................................................................................................................................................................................. 389 Diagnostic Information and Procedures............................................................................................................................................................................................ 389 Fuel Pressure Inspection..................................................................................................................................................................................................... 389 Fuel Cut Operation Inspection................................................................................................................................................................................................ 390 Repair Instructions.............................................................................................................................................................................................................. 391 Fuel System Components....................................................................................................................................................................................................... 391 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 392 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 394 Fuel Leakage Check Procedure................................................................................................................................................................................................. 394 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 394 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 394 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 395 Fuel Injector Removal and Installation....................................................................................................................................................................................... 395 Fuel Injector Inspection..................................................................................................................................................................................................... 396 Fuel Filler Cap Inspection................................................................................................................................................................................................... 397 Fuel Tank Inlet Valve Removal and Installation............................................................................................................................................................................... 398 Fuel Tank Inlet Valve Inspection............................................................................................................................................................................................. 399 Fuel Tank Removal and Installation........................................................................................................................................................................................... 399 Fuel Tank Inspection......................................................................................................................................................................................................... 401 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 401 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 401 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 402 Main Fuel Level Sensor Removal and Installation.............................................................................................................................................................................. 403 Fuel Pump Inspection......................................................................................................................................................................................................... 403 Sub Fuel Level Sensor Removal and Installation (For 4WD model)............................................................................................................................................................... 404 Sub Fuel Level Sensor Inspection (For 4WD model)............................................................................................................................................................................. 404 Specifications................................................................................................................................................................................................................... 404 Tightening Torque Specifications............................................................................................................................................................................................. 404 Special Tools and Equipment...................................................................................................................................................................................................... 405 Special Tool................................................................................................................................................................................................................. 405 Ignition System...................................................................................................................................................................................................................... 406 General Description.............................................................................................................................................................................................................. 406 Ignition System Construction................................................................................................................................................................................................. 406 Schematic and Routing Diagram.................................................................................................................................................................................................... 407 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 407 Component Location............................................................................................................................................................................................................... 408 Ignition System Components Location.......................................................................................................................................................................................... 408 Diagnostic Information and Procedures............................................................................................................................................................................................ 409 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 409 Reference Waveform of Ignition System........................................................................................................................................................................................ 409 Ignition System Check........................................................................................................................................................................................................ 409 Ignition Spark Test.......................................................................................................................................................................................................... 411 Repair Instructions.............................................................................................................................................................................................................. 411 High-Tension Cord Removal and Installation................................................................................................................................................................................... 411 High-Tension Cord Inspection................................................................................................................................................................................................. 412 Spark Plug Removal and Installation.......................................................................................................................................................................................... 412 Spark Plug Inspection........................................................................................................................................................................................................ 412 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................................................................................................... 413 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................................................................................................ 413 Ignition Timing Inspection................................................................................................................................................................................................... 413 Specifications................................................................................................................................................................................................................... 414 Tightening Torque Specifications............................................................................................................................................................................................. 414 Special Tools and Equipment...................................................................................................................................................................................................... 414 Special Tool................................................................................................................................................................................................................. 414 Starting System...................................................................................................................................................................................................................... 415 Schematic and Routing Diagram.................................................................................................................................................................................................... 415 Cranking System Circuit Diagram.............................................................................................................................................................................................. 415 Diagnostic Information and Procedures............................................................................................................................................................................................ 415 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 415 Cranking System Test......................................................................................................................................................................................................... 417 Repair Instructions.............................................................................................................................................................................................................. 418 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 418 Starting Motor Components.................................................................................................................................................................................................... 419 Starting Motor Inspection.................................................................................................................................................................................................... 420 Specifications................................................................................................................................................................................................................... 423 Cranking System Specifications............................................................................................................................................................................................... 423 Tightening Torque Specifications............................................................................................................................................................................................. 423 Special Tools and Equipment...................................................................................................................................................................................................... 423 Recommended Service Material................................................................................................................................................................................................. 423 Charging System...................................................................................................................................................................................................................... 424 General Description.............................................................................................................................................................................................................. 424 Battery Description.......................................................................................................................................................................................................... 424 Generator Description........................................................................................................................................................................................................ 426 Diagnostic Information and Procedures............................................................................................................................................................................................ 427 Battery Inspection........................................................................................................................................................................................................... 427 Generator Symptom Diagnosis.................................................................................................................................................................................................. 427 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 428 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 429 Repair Instructions.............................................................................................................................................................................................................. 429 Jump Starting in Case of Emergency........................................................................................................................................................................................... 429 Battery Dismounting and Remounting........................................................................................................................................................................................... 430 Generator Dismounting and Remounting......................................................................................................................................................................................... 430 Generator Components......................................................................................................................................................................................................... 431 Generator Inspection......................................................................................................................................................................................................... 431 Specifications................................................................................................................................................................................................................... 433 Charging System Specifications............................................................................................................................................................................................... 433 Tightening Torque Specifications............................................................................................................................................................................................. 433 Exhaust System....................................................................................................................................................................................................................... 434 General Description.............................................................................................................................................................................................................. 434 Exhaust System Description................................................................................................................................................................................................... 434 Diagnostic Information and Procedures............................................................................................................................................................................................ 434 Exhaust System Check......................................................................................................................................................................................................... 434 Repair Instructions.............................................................................................................................................................................................................. 435 Exhaust System Components.................................................................................................................................................................................................... 435 Exhaust Manifold Removal and Installation.................................................................................................................................................................................... 436 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 438 Specifications................................................................................................................................................................................................................... 438 Tightening Torque Specifications............................................................................................................................................................................................. 438 Suspension............................................................................................................................................................................................................................... 439 Precautions.......................................................................................................................................................................................................................... 441 Precautions...................................................................................................................................................................................................................... 441 Precautions on Suspension.................................................................................................................................................................................................... 441 Suspension General Diagnosis......................................................................................................................................................................................................... 442 Diagnostic Information and Procedures............................................................................................................................................................................................ 442 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 442 Specifications................................................................................................................................................................................................................... 444 Wheel Alignment Specifications............................................................................................................................................................................................... 444 Front Suspension..................................................................................................................................................................................................................... 446 General Description.............................................................................................................................................................................................................. 446 Front Suspension Construction................................................................................................................................................................................................ 446 Front Wheel Alignment Construction........................................................................................................................................................................................... 447 Repair Instructions.............................................................................................................................................................................................................. 448 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 448 Front Strut Assembly Components.............................................................................................................................................................................................. 450 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 451 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 453 Front Strut Assembly Check................................................................................................................................................................................................... 455 Front Wheel Hub and Steering Knuckle Components.............................................................................................................................................................................. 455 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................................................................................................. 456 Front Wheel Hub, Disc, Nut and Bearing Check................................................................................................................................................................................. 459 Suspension Control Arm / Bushing Removal and Installation.................................................................................................................................................................... 460 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 461 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 462 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 462 Suspension Control Arm Joint Check........................................................................................................................................................................................... 462 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 463 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 463 Front Suspension Frame Check................................................................................................................................................................................................. 467 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 467 Front Suspension Fasteners Check............................................................................................................................................................................................. 467 Specifications................................................................................................................................................................................................................... 468 Tightening Torque Specifications............................................................................................................................................................................................. 468 Special Tools and Equipment...................................................................................................................................................................................................... 469 Special Tool................................................................................................................................................................................................................. 469 Rear Suspension...................................................................................................................................................................................................................... 470 General Description.............................................................................................................................................................................................................. 470 Rear Suspension Construction................................................................................................................................................................................................. 470 Component Location............................................................................................................................................................................................................... 472 Rear Suspension Component Location........................................................................................................................................................................................... 472 Repair Instructions.............................................................................................................................................................................................................. 474 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 474 Rear Shock Absorber Inspection............................................................................................................................................................................................... 475 Rear Shock Absorber Bush Removal and Installation............................................................................................................................................................................ 475 Rear Shock Absorber Bush Inspection.......................................................................................................................................................................................... 476 Coil Spring Removal and Installation......................................................................................................................................................................................... 476 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................................................................................................. 477 Spring Upper Seat and Lower Seat Removal and Installation.................................................................................................................................................................... 477 Rear Axle Removal and Installation (2WD Vehicle)............................................................................................................................................................................. 478 Rear Axle Removal and Installation (4WD Vehicle)............................................................................................................................................................................. 482 Trailing Arm, Rear Axle and Coil Spring Inspection........................................................................................................................................................................... 485 Rear Axle Bush Inspection.................................................................................................................................................................................................... 485 Wheel Bearing and Wheel Stud Bolt Removal and Installation (2WD Vehicle)..................................................................................................................................................... 485 Wheel Bearing and Wheel Stud Bolt Removal and Installation (4WD Vehicle)..................................................................................................................................................... 487 Rear Wheel Disc, Nut and Bearing Inspection.................................................................................................................................................................................. 488 Spindle Removal and Installation (2WD Vehicle)............................................................................................................................................................................... 488 Spindle Inspection........................................................................................................................................................................................................... 489 Rear Axle Flange Removal and Installation (4WD Vehicle)...................................................................................................................................................................... 490 Rear Wheel Hub and Rear Axle Flange Inspection (4WD Vehicle)................................................................................................................................................................. 491 Rear Suspension Fasteners Inspection......................................................................................................................................................................................... 491 Specifications................................................................................................................................................................................................................... 492 Tightening Torque Specifications............................................................................................................................................................................................. 492 Special Tools and Equipment...................................................................................................................................................................................................... 492 Special Tool................................................................................................................................................................................................................. 492 Wheels and Tires..................................................................................................................................................................................................................... 493 General Description.............................................................................................................................................................................................................. 493 Tires Description............................................................................................................................................................................................................ 493 Wheels Description........................................................................................................................................................................................................... 494 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 495 Wear Indicators Description.................................................................................................................................................................................................. 495 Radial Tire Waddle Description............................................................................................................................................................................................... 496 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 497 Balancing Wheels Description................................................................................................................................................................................................. 497 Repair Instructions.............................................................................................................................................................................................................. 498 General Balance Procedures................................................................................................................................................................................................... 498 Tire Rotation................................................................................................................................................................................................................ 498 Wheel Removal and Installation............................................................................................................................................................................................... 499 Tire Mounting and Dismounting................................................................................................................................................................................................ 499 Tire Repair.................................................................................................................................................................................................................. 499 Specifications................................................................................................................................................................................................................... 500 Wheels and Tires Specifications.............................................................................................................................................................................................. 500 Tightening Torque Specifications............................................................................................................................................................................................. 500 Driveline / Axle......................................................................................................................................................................................................................... 501 Precautions.......................................................................................................................................................................................................................... 503 Precautions...................................................................................................................................................................................................................... 503 Precautions on Driveline / Axle.............................................................................................................................................................................................. 503 Drive Shaft / Axle................................................................................................................................................................................................................... 504 Front............................................................................................................................................................................................................................ 504 General Description.......................................................................................................................................................................................................... 504 Front Drive Shaft Construction........................................................................................................................................................................................... 504 Component Location........................................................................................................................................................................................................... 504 Front Drive Shaft Assembly Components Location........................................................................................................................................................................... 504 Diagnostic Information and Procedures........................................................................................................................................................................................ 505 Front Drive Shaft Symptom Diagnosis...................................................................................................................................................................................... 505 Repair Instructions.......................................................................................................................................................................................................... 506 Front Drive Shaft Components............................................................................................................................................................................................. 506 Front Drive Shaft Assembly On-Vehicle Inspection......................................................................................................................................................................... 507 Front Drive Shaft Assembly Removal and Installation...................................................................................................................................................................... 507 Front Drive Shaft Disassembly and Reassembly............................................................................................................................................................................. 509 Center Shaft and Center Bearing Support Disassembly and Reassembly....................................................................................................................................................... 516 Front Drive Shaft Inspection............................................................................................................................................................................................. 516 Specifications............................................................................................................................................................................................................... 517 Tightening Torque Specifications......................................................................................................................................................................................... 517 Special Tools and Equipment.................................................................................................................................................................................................. 517 Recommended Service Material............................................................................................................................................................................................. 517 Special Tool............................................................................................................................................................................................................. 517 Rear............................................................................................................................................................................................................................. 518 General Description.......................................................................................................................................................................................................... 518 Rear Drive Shaft Description............................................................................................................................................................................................. 518 Repair Instructions.......................................................................................................................................................................................................... 518 Rear Drive Shaft Components.............................................................................................................................................................................................. 518 Rear Drive Shaft Removal and Installation................................................................................................................................................................................ 519 Rear Drive Shaft Disassembly and Reassembly.............................................................................................................................................................................. 519 Specifications............................................................................................................................................................................................................... 520 Tightening Torque Specifications......................................................................................................................................................................................... 520 Special Tools and Equipment.................................................................................................................................................................................................. 520 Recommended Service Material............................................................................................................................................................................................. 520 Differential......................................................................................................................................................................................................................... 521 Precautions...................................................................................................................................................................................................................... 521 Precaution for Rear Differential Oil Leakage................................................................................................................................................................................. 521 General Description.............................................................................................................................................................................................................. 521 Rear Differential Description................................................................................................................................................................................................ 521 Diagnostic Information and Procedures............................................................................................................................................................................................ 521 Rear Differential Symptom Diagnosis.......................................................................................................................................................................................... 521 Repair Instructions.............................................................................................................................................................................................................. 522 Rear Differential Oil Level Check............................................................................................................................................................................................ 522 Rear Differential Oil Change................................................................................................................................................................................................. 522 Rear Differential Assembly Dismounting and Remounting........................................................................................................................................................................ 523 Rear Differential Components................................................................................................................................................................................................. 524 Rear Differential Disassembly and Reassembly................................................................................................................................................................................. 525 Rear Differential Inspection................................................................................................................................................................................................. 534 Specifications................................................................................................................................................................................................................... 535 Tightening Torque Specifications............................................................................................................................................................................................. 535 Special Tools and Equipment...................................................................................................................................................................................................... 535 Recommended Service Material................................................................................................................................................................................................. 535 Special Tool................................................................................................................................................................................................................. 535 Transfer............................................................................................................................................................................................................................. 537 General Description.............................................................................................................................................................................................................. 537 Transfer Description......................................................................................................................................................................................................... 537 Diagnostic Information and Procedures............................................................................................................................................................................................ 538 Transfer Symptom Diagnosis................................................................................................................................................................................................... 538 Repair Instructions.............................................................................................................................................................................................................. 538 Transfer Oil Level Check..................................................................................................................................................................................................... 538 Transfer Oil Change.......................................................................................................................................................................................................... 538 Transfer Dismounting and Remounting.......................................................................................................................................................................................... 539 Transfer Assembly Components................................................................................................................................................................................................. 541 Transfer Assembly Disassembly and Reassembly................................................................................................................................................................................. 542 Reduction Drive Gear and Reduction Driven Gear Disassembly and Reassembly.................................................................................................................................................... 545 Transfer Right Case and Left Case Disassembly and Reassembly................................................................................................................................................................. 545 Transfer Output Retainer Assembly Disassembly and Reassembly................................................................................................................................................................. 547 Transfer Assembly Inspection................................................................................................................................................................................................. 550 Bevel Gear Tooth Contact Inspection.......................................................................................................................................................................................... 551 Specifications................................................................................................................................................................................................................... 553 Tightening Torque Specifications............................................................................................................................................................................................. 553 Special Tools and Equipment...................................................................................................................................................................................................... 553 Recommended Service Material................................................................................................................................................................................................. 553 Special Tool................................................................................................................................................................................................................. 553 Propeller Shafts..................................................................................................................................................................................................................... 555 General Description.............................................................................................................................................................................................................. 555 Propeller Shaft Description.................................................................................................................................................................................................. 555 Repair Instructions.............................................................................................................................................................................................................. 555 Propeller Shaft Components................................................................................................................................................................................................... 555 Propeller Shaft Removal and Installation..................................................................................................................................................................................... 556 Propeller Shaft Inspection................................................................................................................................................................................................... 557 Propeller Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 557 Coupling Assembly Disassembly and Reassembly................................................................................................................................................................................. 557 Specifications................................................................................................................................................................................................................... 559 Tightening Torque Specifications............................................................................................................................................................................................. 559 Special Tools and Equipment...................................................................................................................................................................................................... 559 Special Tool................................................................................................................................................................................................................. 559 Brakes................................................................................................................................................................................................................................... 561 Precautions.......................................................................................................................................................................................................................... 563 Precautions...................................................................................................................................................................................................................... 563 Precautions for Brakes....................................................................................................................................................................................................... 563 Brake Control System and Diagnosis................................................................................................................................................................................................... 564 Precautions...................................................................................................................................................................................................................... 564 Precautions on Brake......................................................................................................................................................................................................... 564 General Description.............................................................................................................................................................................................................. 564 Brakes Construction.......................................................................................................................................................................................................... 564 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 565 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 566 Diagnostic Information and Procedures............................................................................................................................................................................................ 567 Brakes Diagnosis Note........................................................................................................................................................................................................ 567 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 567 Repair Instructions.............................................................................................................................................................................................................. 570 Brake Pedal Free Height Inspection........................................................................................................................................................................................... 570 Brake Pedal Play Inspection.................................................................................................................................................................................................. 570 Excessive Pedal Travel Inspection............................................................................................................................................................................................ 571 Master Cylinder and Brake Fluid Level Inspection............................................................................................................................................................................. 571 Stop Light Switch Adjustment................................................................................................................................................................................................. 572 Air Bleeding of Brake System................................................................................................................................................................................................. 572 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 573 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 574 Brake Hose and Pipe Inspection............................................................................................................................................................................................... 574 Master Cylinder Components................................................................................................................................................................................................... 575 Master Cylinder Reservoir Removal and Installation (2WD Vehicle)............................................................................................................................................................. 577 Master Cylinder Reservoir Removal and Installation (4WD Vehicle)............................................................................................................................................................. 578 Master Cylinder Assembly Removal and Installation (2WD Vehicle).............................................................................................................................................................. 578 Master Cylinder Assembly Removal and Installation (4WD Vehicle).............................................................................................................................................................. 580 Master Cylinder Assembly Disassembly and Assembly (2WD Vehicle).............................................................................................................................................................. 582 Master Cylinder Assembly Inspection (2WD Vehicle)............................................................................................................................................................................ 583 Master Cylinder Assembly Inspection (4WD Vehicle)............................................................................................................................................................................ 583 Brake Booster Components..................................................................................................................................................................................................... 584 Booster Operation Inspection................................................................................................................................................................................................. 585 Brake Booster Removal and Installation....................................................................................................................................................................................... 586 Brake Booster Inspection and Adjustment...................................................................................................................................................................................... 587 Specifications................................................................................................................................................................................................................... 588 Tightening Torque Specifications............................................................................................................................................................................................. 588 Special Tools and Equipment...................................................................................................................................................................................................... 588 Recommended Service Material................................................................................................................................................................................................. 588 Front Brakes......................................................................................................................................................................................................................... 589 Repair Instructions.............................................................................................................................................................................................................. 589 Front Disc Brake Components.................................................................................................................................................................................................. 589 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................... 590 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 590 Front Disc Brake Pad Inspection.............................................................................................................................................................................................. 591 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 592 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 593 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 595 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 595 Front Brake Disc Inspection.................................................................................................................................................................................................. 596 Specifications................................................................................................................................................................................................................... 597 Tightening Torque Specifications............................................................................................................................................................................................. 597 Special Tools and Equipment...................................................................................................................................................................................................... 597 Recommended Service Material................................................................................................................................................................................................. 597 Special Tool................................................................................................................................................................................................................. 597 Rear Brakes.......................................................................................................................................................................................................................... 598 Repair Instructions.............................................................................................................................................................................................................. 598 Rear Drum Brake Components................................................................................................................................................................................................... 598 Rear Brake Drum Removal and Installation..................................................................................................................................................................................... 599 Rear Brake Drum and Shoe Inspection.......................................................................................................................................................................................... 600 Rear Brake Shoe Removal and Installation..................................................................................................................................................................................... 601 Rear Brake Shoe Inspection................................................................................................................................................................................................... 602 Wheel Cylinder Removal and Installation...................................................................................................................................................................................... 602 Wheel Cylinder Inspection.................................................................................................................................................................................................... 603 Brake Back Plate Removal and Installation (2WD Vehicle)...................................................................................................................................................................... 603 Brake Back Plate Removal and Installation (4WD Vehicle)...................................................................................................................................................................... 604 Specifications................................................................................................................................................................................................................... 605 Tightening Torque Specifications............................................................................................................................................................................................. 605 Special Tools and Equipment...................................................................................................................................................................................................... 605 Recommended Service Material................................................................................................................................................................................................. 605 Special Tool................................................................................................................................................................................................................. 605 Parking Brake........................................................................................................................................................................................................................ 606 General Description.............................................................................................................................................................................................................. 606 Parking Brake Cable Construction............................................................................................................................................................................................. 606 Repair Instructions.............................................................................................................................................................................................................. 607 Parking Brake Inspection and Adjustment...................................................................................................................................................................................... 607 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 608 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 608 Specifications................................................................................................................................................................................................................... 609 Tightening Torque Specifications............................................................................................................................................................................................. 609 Special Tools and Equipment...................................................................................................................................................................................................... 609 Recommended Service Material................................................................................................................................................................................................. 609 ABS.................................................................................................................................................................................................................................. 610 Precautions...................................................................................................................................................................................................................... 610 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 610 Precautions in On-Vehicle Service............................................................................................................................................................................................ 610 General Description.............................................................................................................................................................................................................. 611 ABS Description.............................................................................................................................................................................................................. 611 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 611 Schematic and Routing Diagram.................................................................................................................................................................................................... 612 ABS Schematic................................................................................................................................................................................................................ 612 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 613 Component Location............................................................................................................................................................................................................... 614 ABS Components Location...................................................................................................................................................................................................... 614 Front Wheel Speed Sensor Components Location................................................................................................................................................................................. 615 Rear Wheel Speed Sensor Components Location.................................................................................................................................................................................. 615 Diagnostic Information and Procedures............................................................................................................................................................................................ 616 ABS Check.................................................................................................................................................................................................................... 616 ABS Warning Lamp Check....................................................................................................................................................................................................... 618 EBD Warning Lamp (Brake Warning Lamp) Check.................................................................................................................................................................................. 618 DTC Check.................................................................................................................................................................................................................... 619 DTC Table.................................................................................................................................................................................................................... 619 DTC Clearance................................................................................................................................................................................................................ 620 Scan Tool Data............................................................................................................................................................................................................... 620 ABS Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................... 621 ABS Warning Lamp Comes ON Steady............................................................................................................................................................................................. 622 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON............................................................................................................................................................ 624 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady........................................................................................................................................................................ 625 Serial Data Link Circuit Check............................................................................................................................................................................................... 626 DTC C1015: G Sensor Circuit.................................................................................................................................................................................................. 628 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring.................................................................. 628 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit.... 630 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 631 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 632 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 633 DTC C1071: ABS Control Module................................................................................................................................................................................................ 634 Repair Instructions.............................................................................................................................................................................................................. 635 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 635 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 636 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 636 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 636 Front Wheel Speed Sensor On-Vehicle Inspection............................................................................................................................................................................... 638 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 638 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 639 Rear Wheel Speed Sensor On-Vehicle Inspection................................................................................................................................................................................ 639 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 640 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 641 Front Wheel Speed Sensor Ring On-Vehicle Inspection.......................................................................................................................................................................... 641 Front Wheel Speed Sensor Ring Removal and Installation....................................................................................................................................................................... 641 Rear Wheel Speed Sensor Ring On-Vehicle Inspection........................................................................................................................................................................... 642 Rear Wheel Speed Sensor Ring Removal and Installation (2WD Vehicle).......................................................................................................................................................... 642 Rear Wheel Speed Sensor Ring Removal and Installation (4WD Vehicle).......................................................................................................................................................... 642 ABS Sensor Ring Inspection................................................................................................................................................................................................... 642 Specifications................................................................................................................................................................................................................... 643 Tightening Torque Specifications............................................................................................................................................................................................. 643 Special Tools and Equipment...................................................................................................................................................................................................... 643 Special Tool................................................................................................................................................................................................................. 643 Transmission / Transaxle................................................................................................................................................................................................................. 645 Precautions.......................................................................................................................................................................................................................... 649 Precautions...................................................................................................................................................................................................................... 649 Precautions on Transmission / Transaxle...................................................................................................................................................................................... 649 Automatic Transmission/Transaxle..................................................................................................................................................................................................... 650 Precautions...................................................................................................................................................................................................................... 650 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 650 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 650 General Description.............................................................................................................................................................................................................. 652 A/T Description.............................................................................................................................................................................................................. 652 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................................................................................................. 655 Table of Component Operation................................................................................................................................................................................................. 656 A/T Diagnosis General Description............................................................................................................................................................................................ 657 On-Board Diagnostic System Description....................................................................................................................................................................................... 657 CAN Communication System Description......................................................................................................................................................................................... 659 Schematic and Routing Diagram.................................................................................................................................................................................................... 660 Transmission Control Module (TCM) Wiring Diagram............................................................................................................................................................................. 660 Automatic Gear Shift Table................................................................................................................................................................................................... 662 Component Location............................................................................................................................................................................................................... 664 Electronic Shift Control System Components Location.......................................................................................................................................................................... 664 Diagnostic Information and Procedures............................................................................................................................................................................................ 666 A/T System Check............................................................................................................................................................................................................. 666 Visual Inspection............................................................................................................................................................................................................ 668 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 669 Transmission Warning Light Check............................................................................................................................................................................................. 669 DTC Table.................................................................................................................................................................................................................... 670 DTC Check.................................................................................................................................................................................................................... 672 DTC Clearance................................................................................................................................................................................................................ 673 Fail-Safe Table.............................................................................................................................................................................................................. 674 Scan Tool Data............................................................................................................................................................................................................... 676 A/T Basic Check.............................................................................................................................................................................................................. 679 Road Test.................................................................................................................................................................................................................... 680 Manual Road Test............................................................................................................................................................................................................. 682 Engine Brake Test............................................................................................................................................................................................................ 683 Stall Test................................................................................................................................................................................................................... 683 Time Lag Test................................................................................................................................................................................................................ 684 Line Pressure Test........................................................................................................................................................................................................... 685 “P” Range Test............................................................................................................................................................................................................... 685 A/T Symptom Diagnosis........................................................................................................................................................................................................ 686 No Gear Shift to 4th gear.................................................................................................................................................................................................... 693 No Lock-Up Occurs............................................................................................................................................................................................................ 694 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON.................................................................................................................................... 695 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON.......................................................................................................................................... 695 DTC P0705: Transmission Range Sensor Circuit Malfunction..................................................................................................................................................................... 696 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................................................................................................. 698 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low................................................................................................................................................................. 700 DTC P0713: Transmission Fluid Temperature Sensor Circuit High................................................................................................................................................................ 701 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction.................................................................................................................................................................. 702 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal....................................................................................................................................................................... 704 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON............................................................................................................................................... 705 DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction................................................................................................................................................................ 706 DTC P0787: Shift / Timing Solenoid Control Circuit Low....................................................................................................................................................................... 708 DTC P0788: Shift / Timing Solenoid Control Circuit High...................................................................................................................................................................... 710 DTC P0962: Pressure Control Solenoid Control Circuit Low..................................................................................................................................................................... 712 DTC P0963: Pressure Control Solenoid Control Circuit High.................................................................................................................................................................... 714 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low................................................................................................................. 716 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High.................................................................................................................................... 718 DTC P1702: Internal Control Module Memory Check Sum Error.................................................................................................................................................................... 720 DTC P1703: Can Invalid Data - TCM............................................................................................................................................................................................ 720 DTC P1723: Range Select Switch Malfunction................................................................................................................................................................................... 721 DTC P1774: Control Module Communication Bus Off.............................................................................................................................................................................. 722 DTC P1775: High Speed CAN Communication Bus Off (Transmission Error)......................................................................................................................................................... 727 DTC P1777: TCM Lost Communication with ECM (Reception Error)................................................................................................................................................................. 730 DTC P1778: TCM Lost Communication with BCM (Reception Error)................................................................................................................................................................. 733 DTC P1878: Torque Converter Clutch Shudder................................................................................................................................................................................... 736 DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High...................................................................................................................................... 736 DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low............................................................................................................................... 739 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 741 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 745 Brake Interlock System Inspection............................................................................................................................................................................................ 746 Repair Instructions.............................................................................................................................................................................................................. 747 Learning Control Initialization.............................................................................................................................................................................................. 747 A/T Fluid Level Check........................................................................................................................................................................................................ 747 A/T Fluid Change............................................................................................................................................................................................................. 748 Selector Lever Components.................................................................................................................................................................................................... 748 Select Lever Assembly Installation........................................................................................................................................................................................... 749 Select Lever Knob Installation............................................................................................................................................................................................... 749 Selector Lever Inspection.................................................................................................................................................................................................... 749 Select Cable Components...................................................................................................................................................................................................... 749 Select Cable Removal and Installation........................................................................................................................................................................................ 750 Select Cable Adjustment...................................................................................................................................................................................................... 750 Transmission Range Sensor (Shift Switch) Inspection and Adjustment........................................................................................................................................................... 751 Output Shaft Speed Sensor (VSS) Removal and Installation..................................................................................................................................................................... 751 Output Shaft Speed Sensor (VSS) Inspection................................................................................................................................................................................... 752 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 752 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 752 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 753 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 753 “3” Position Switch Inspection............................................................................................................................................................................................... 754 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation................................................................................................................................... 754 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection................................................................................................................................................ 755 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...................................................................................................... 757 Pressure Control Solenoid Valve Inspection................................................................................................................................................................................... 757 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 758 A/T Relay Inspection......................................................................................................................................................................................................... 759 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 759 Shift Lock Solenoid Inspection............................................................................................................................................................................................... 760 Shift Lock Solenoid Replacement.............................................................................................................................................................................................. 760 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 761 A/T Fluid Cooler Hoses Replacement........................................................................................................................................................................................... 762 Automatic Transaxle Unit Components.......................................................................................................................................................................................... 762 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................... 763 Automatic Transaxle Assembly Components...................................................................................................................................................................................... 765 Automatic Transaxle Unit Disassembly......................................................................................................................................................................................... 766 Oil Pump Assembly Components................................................................................................................................................................................................. 778 Oil Pump Assembly Disassembly and Reassembly................................................................................................................................................................................. 779 Oil Pump Assembly Inspection................................................................................................................................................................................................. 779 Direct Clutch Assembly Components............................................................................................................................................................................................ 781 Direct Clutch Assembly Preliminary Check..................................................................................................................................................................................... 781 Direct Clutch Assembly Disassembly and Reassembly............................................................................................................................................................................ 782 Direct Clutch Assembly Inspection............................................................................................................................................................................................ 784 Forward and Reverse Clutch Assembly Components............................................................................................................................................................................... 785 Forward and Reverse Clutch Assembly Preliminary Check........................................................................................................................................................................ 786 Forward and Reverse Clutch Assembly Disassembly and Reassembly............................................................................................................................................................... 786 Forward and Reverse Clutch Assembly Inspection............................................................................................................................................................................... 790 2nd Brake Piston Assembly Components......................................................................................................................................................................................... 791 2nd Brake Piston Assembly Disassembly and Reassembly......................................................................................................................................................................... 791 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components.................................................................................................................................................... 792 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly.................................................................................................................................... 793 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection.................................................................................................................................................... 794 Countershaft Assembly Components............................................................................................................................................................................................. 795 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 795 Valve Body Assembly Components............................................................................................................................................................................................... 796 Valve Body Assembly Disassembly and Reassembly............................................................................................................................................................................... 797 Differential Assembly Components............................................................................................................................................................................................. 798 Differential Assembly Disassembly and Reassembly............................................................................................................................................................................. 799 Differential Assembly Inspection............................................................................................................................................................................................. 800 Torque Converter Housing Disassembly and Reassembly.......................................................................................................................................................................... 801 Transaxle Case Disassembly and Reassembly.................................................................................................................................................................................... 803 Automatic Transaxle Unit Inspection and Adjustment........................................................................................................................................................................... 804 Automatic Transaxle Unit Assembly............................................................................................................................................................................................ 807 Specifications................................................................................................................................................................................................................... 826 Tightening Torque Specifications............................................................................................................................................................................................. 826 Special Tools and Equipment...................................................................................................................................................................................................... 827 Recommended Service Material................................................................................................................................................................................................. 827 Special Tool................................................................................................................................................................................................................. 827 Manual Transmission/Transaxle........................................................................................................................................................................................................ 830 For M13 Engine Model............................................................................................................................................................................................................. 830 General Description.......................................................................................................................................................................................................... 830 Manual Transaxle Construction and Servicing.............................................................................................................................................................................. 830 Diagnostic Information and Procedures........................................................................................................................................................................................ 833 Manual Transaxle Symptom Diagnosis....................................................................................................................................................................................... 833 Repair Instructions.......................................................................................................................................................................................................... 833 Manual Transaxle Oil Change.............................................................................................................................................................................................. 833 Differential Side Oil Seal Replacement................................................................................................................................................................................... 834 Gear Shift Control Lever and Cable Components............................................................................................................................................................................ 835 Gear Shift Control Lever and Cable Removal and Installation.............................................................................................................................................................. 836 Gear Select Control Cable Adjustment..................................................................................................................................................................................... 836 Vehicle Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................... 837 Back Up Lamp Switch Removal and Installation............................................................................................................................................................................. 837 Back Up Lamp Switch Inspection........................................................................................................................................................................................... 838 Manual Transaxle Unit Components......................................................................................................................................................................................... 838 Manual Transaxle Unit Dismounting and Remounting......................................................................................................................................................................... 839 Gear Shift and Select Shaft Assembly Components.......................................................................................................................................................................... 841 Gear Shift and Select Shaft Assembly Removal and Installation............................................................................................................................................................ 842 Gear Shift and Select Shaft Disassembly and Assembly..................................................................................................................................................................... 843 Manual Transaxle Assembly Components..................................................................................................................................................................................... 844 Fifth Gear Disassembly and Assembly...................................................................................................................................................................................... 845 Manual Transaxle Assembly Disassembly and Reassembly..................................................................................................................................................................... 848 Transaxle Right Case Disassembly and Assembly............................................................................................................................................................................ 852 Transaxle Left Case Disassembly and Assembly............................................................................................................................................................................. 853 Input Shaft and Countershaft Components.................................................................................................................................................................................. 854 Input Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 855 Countershaft Assembly Disassembly and Reassembly......................................................................................................................................................................... 857 Synchronizer Parts Inspection............................................................................................................................................................................................ 860 Gear Shift Shaft Components.............................................................................................................................................................................................. 861 5th and Reverse Gear Shift Shafts Disassembly and Assembly............................................................................................................................................................... 861 Gear Shift Shaft and Fork Inspection..................................................................................................................................................................................... 862 Differential Components.................................................................................................................................................................................................. 862 Differential Disassembly and Assembly.................................................................................................................................................................................... 863 Specifications............................................................................................................................................................................................................... 865 Tightening Torque Specifications......................................................................................................................................................................................... 865 Special Tools and Equipment.................................................................................................................................................................................................. 866 Recommended Service Material............................................................................................................................................................................................. 866 Special Tool............................................................................................................................................................................................................. 866 For M15 Engine Model............................................................................................................................................................................................................. 868 General Description.......................................................................................................................................................................................................... 868 Manual Transaxle Construction and Servicing.............................................................................................................................................................................. 868 Diagnostic Information and Procedures........................................................................................................................................................................................ 870 Manual Transaxle Symptom Diagnosis....................................................................................................................................................................................... 870 Repair Instructions.......................................................................................................................................................................................................... 870 Manual Transaxle Oil Change.............................................................................................................................................................................................. 870 Differential Side Oil Seal Replacement................................................................................................................................................................................... 871 Gear Shift Control Lever and Cable Components............................................................................................................................................................................ 872 Gear Shift Control Lever and Cable Removal and Installation.............................................................................................................................................................. 873 Gear Select Control Cable Adjustment..................................................................................................................................................................................... 873 Vehicle Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................... 874 Back Up Lamp Switch Removal and Installation............................................................................................................................................................................. 874 Back Up Lamp Switch Inspection........................................................................................................................................................................................... 875 Manual Transaxle Unit Components......................................................................................................................................................................................... 875 Manual Transaxle Unit Dismounting and Remounting......................................................................................................................................................................... 876 Gear Shift and Select Shaft Assembly Components.......................................................................................................................................................................... 878 Gear Shift and Select Shaft Assembly Removal and Installation............................................................................................................................................................ 878 Gear Shift and Select Shaft Disassembly and Assembly..................................................................................................................................................................... 879 Manual Transaxle Assembly Components..................................................................................................................................................................................... 880 Fifth Gear Disassembly and Assembly...................................................................................................................................................................................... 881 Manual Transaxle Assembly Disassembly and Reassembly..................................................................................................................................................................... 884 Transaxle Right Case Disassembly and Assembly............................................................................................................................................................................ 890 Transaxle Left Case Disassembly and Assembly............................................................................................................................................................................. 891 Input Shaft and Countershaft Components.................................................................................................................................................................................. 892 Input Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 893 Countershaft Assembly Disassembly and Reassembly......................................................................................................................................................................... 895 Synchronizer Parts Inspection............................................................................................................................................................................................ 898 Gear Shift Shaft Components.............................................................................................................................................................................................. 898 5th and Reverse Gear Shift Shafts Disassembly and Assembly............................................................................................................................................................... 899 Gear Shift Shaft and Fork Inspection..................................................................................................................................................................................... 899 Differential Components.................................................................................................................................................................................................. 900 Differential Disassembly and Assembly.................................................................................................................................................................................... 900 Specifications............................................................................................................................................................................................................... 902 Tightening Torque Specifications......................................................................................................................................................................................... 902 Special Tools and Equipment.................................................................................................................................................................................................. 903 Recommended Service Material............................................................................................................................................................................................. 903 Special Tool............................................................................................................................................................................................................. 903 Clutch............................................................................................................................................................................................................................... 906 General Description.............................................................................................................................................................................................................. 906 Clutch Construction.......................................................................................................................................................................................................... 906 Diagnostic Information and Procedures............................................................................................................................................................................................ 907 Clutch System Symptom Diagnosis.............................................................................................................................................................................................. 907 Repair Instructions.............................................................................................................................................................................................................. 908 Clutch Pedal Inspection...................................................................................................................................................................................................... 908 Clutch Fluid Level Inspection................................................................................................................................................................................................ 908 Air Bleeding of Clutch System................................................................................................................................................................................................ 909 Clutch Fluid Pipe and Hose Components........................................................................................................................................................................................ 910 Clutch Fluid Pipe Removal and Installation................................................................................................................................................................................... 911 Clutch Fluid Pipe Inspection................................................................................................................................................................................................. 911 Clutch Master Cylinder Removal and Installation.............................................................................................................................................................................. 912 Clutch Operating Cylinder Removal and Installation........................................................................................................................................................................... 912 Clutch Pedal and Clutch Pedal Bracket Components............................................................................................................................................................................. 913 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................................................................................................ 914 Clutch Cover, Clutch Disc and Flywheel Removal and Installation.............................................................................................................................................................. 914 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................................................................................................ 916 Clutch Release System Removal and Installation............................................................................................................................................................................... 917 Clutch Release System Inspection............................................................................................................................................................................................. 919 Specifications................................................................................................................................................................................................................... 920 Tightening Torque Specifications............................................................................................................................................................................................. 920 Special Tools and Equipment...................................................................................................................................................................................................... 920 Recommended Service Material................................................................................................................................................................................................. 920 Special Tool................................................................................................................................................................................................................. 921 Steering................................................................................................................................................................................................................................. 923 Precautions.......................................................................................................................................................................................................................... 925 Precautions...................................................................................................................................................................................................................... 925 Precautions on Steering...................................................................................................................................................................................................... 925 Steering General Diagnosis........................................................................................................................................................................................................... 926 Precautions...................................................................................................................................................................................................................... 926 Precautions for Steering Diagnosis........................................................................................................................................................................................... 926 Diagnostic Information and Procedures............................................................................................................................................................................................ 927 Steering Symptom Diagnosis................................................................................................................................................................................................... 927 Steering Wheel and Column............................................................................................................................................................................................................ 928 Precautions...................................................................................................................................................................................................................... 928 Service Precautions of Steering Wheel and Column............................................................................................................................................................................. 928 Diagnostic Information and Procedures............................................................................................................................................................................................ 928 Checking Steering Column for Accident Damage................................................................................................................................................................................. 928 Repair Instructions.............................................................................................................................................................................................................. 929 Steering Wheel and Column Construction....................................................................................................................................................................................... 929 Steering Wheel Removal and Installation...................................................................................................................................................................................... 930 Contact Coil Cable Assembly Removal and Installation......................................................................................................................................................................... 931 Centering Contact Coil Cable Assembly........................................................................................................................................................................................ 932 Contact Coil Cable Assembly Inspection....................................................................................................................................................................................... 932 Steering Column Removal and Installation..................................................................................................................................................................................... 932 Steering Column Inspection................................................................................................................................................................................................... 935 Ignition Switch Cylinder Assembly Removal and Installation (without Keyless Start System).................................................................................................................................... 935 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................ 935 Steering Lower Shaft Removal and Installation................................................................................................................................................................................ 936 Specifications................................................................................................................................................................................................................... 937 Tightening Torque Specifications............................................................................................................................................................................................. 937 Special Tools and Equipment...................................................................................................................................................................................................... 937 Special Tool................................................................................................................................................................................................................. 937 Power Assisted Steering System....................................................................................................................................................................................................... 938 Precautions...................................................................................................................................................................................................................... 938 Steering System Note......................................................................................................................................................................................................... 938 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 938 General Description.............................................................................................................................................................................................................. 939 P/S System Description....................................................................................................................................................................................................... 939 EPS Diagnosis General Description............................................................................................................................................................................................ 940 On-Board Diagnostic System Description....................................................................................................................................................................................... 940 Schematic and Routing Diagram.................................................................................................................................................................................................... 941 EPS System Wiring Circuit Diagram............................................................................................................................................................................................ 941 Diagnostic Information and Procedures............................................................................................................................................................................................ 942 EPS System Check............................................................................................................................................................................................................. 942 “EPS” Warning Lamp Check..................................................................................................................................................................................................... 944 DTC Check.................................................................................................................................................................................................................... 944 DTC Clearance................................................................................................................................................................................................................ 945 DTC Table.................................................................................................................................................................................................................... 945 Scan Tool Data............................................................................................................................................................................................................... 947 P/S System Symptom Diagnosis................................................................................................................................................................................................. 948 Serial Data Link Circuit Check............................................................................................................................................................................................... 949 “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stops................................................................................................................................................... 951 “EPS” Warning Lamp Comes ON Steady even after Engine Starts.................................................................................................................................................................. 953 DTC C1113 / C1117 / C1118: Torque Sensor Circuit Failure..................................................................................................................................................................... 954 DTC C1114: Torque Sensor 5 V Power Supply Circuit Failure.................................................................................................................................................................... 955 DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure................................................................................................................................................................... 957 DTC C1121 / C1123 / C1124: VSS Circuit Failure............................................................................................................................................................................... 959 DTC C1122: Engine Speed Signal Circuit Failure............................................................................................................................................................................... 961 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure..................................................................................................................................................................... 962 DTC C1153: P/S Control Module Power Supply Circuit Voltage Low............................................................................................................................................................... 963 DTC C1155: P/S Control Module Failure........................................................................................................................................................................................ 965 Inspection of P/S Control Module and Its Circuits............................................................................................................................................................................ 965 Steering Wheel Play Check.................................................................................................................................................................................................... 968 Steering Force Check......................................................................................................................................................................................................... 968 Repair Instructions.............................................................................................................................................................................................................. 969 Steering Gear Case Assembly Components....................................................................................................................................................................................... 969 Tie-Rod End Boot On-Vehicle Inspection....................................................................................................................................................................................... 971 Tie-Rod End Removal and Installation......................................................................................................................................................................................... 971 Tie-Rod End Inspection....................................................................................................................................................................................................... 972 Steering Shaft Joint On-Vehicle Inspection................................................................................................................................................................................... 972 Steering Gear Case Assembly Removal and Installation......................................................................................................................................................................... 972 Steering Rack Boot Inspection................................................................................................................................................................................................ 975 Tie-Rod / Rack Boot Removal and Installation................................................................................................................................................................................. 975 Steering Rack Plunger Removal and Installation............................................................................................................................................................................... 977 Steering Rack Plunger Inspection............................................................................................................................................................................................. 977 P/S Control Module Removal and Installation.................................................................................................................................................................................. 977 Torque Sensor Inspection..................................................................................................................................................................................................... 978 Motor Assembly Inspection.................................................................................................................................................................................................... 978 Specifications................................................................................................................................................................................................................... 979 Tightening Torque Specifications............................................................................................................................................................................................. 979 Special Tools and Equipment...................................................................................................................................................................................................... 980 Recommended Service Material................................................................................................................................................................................................. 980 Special Tool................................................................................................................................................................................................................. 980 HVAC..................................................................................................................................................................................................................................... 981 Precautions.......................................................................................................................................................................................................................... 984 Precautions...................................................................................................................................................................................................................... 984 Precautions on HVAC.......................................................................................................................................................................................................... 984 Heater and Ventilation............................................................................................................................................................................................................... 985 General Description.............................................................................................................................................................................................................. 985 Heater and Ventilation Construction.......................................................................................................................................................................................... 985 Schematic and Routing Diagram.................................................................................................................................................................................................... 986 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................ 986 Diagnostic Information and Procedures............................................................................................................................................................................................ 987 Heater and Ventilation Symptom Diagnosis..................................................................................................................................................................................... 987 Repair Instructions.............................................................................................................................................................................................................. 988 HVAC Unit Components......................................................................................................................................................................................................... 988 HVAC Unit Removal and Installation........................................................................................................................................................................................... 988 Blower Motor Removal and Installation........................................................................................................................................................................................ 988 Blower Motor Inspection...................................................................................................................................................................................................... 988 Blower Motor Resistor Removal and Installation............................................................................................................................................................................... 989 Blower Motor Resistor Inspection............................................................................................................................................................................................. 989 Blower Motor Relay Inspection................................................................................................................................................................................................ 990 HVAC Control Unit Components................................................................................................................................................................................................. 990 HVAC Control Unit Removal and Installation................................................................................................................................................................................... 991 Blower Speed Selector Inspection............................................................................................................................................................................................. 993 Air Intake Selector Inspection............................................................................................................................................................................................... 993 Air Intake Control Actuator Removal and Installation......................................................................................................................................................................... 993 Air Intake Control Actuator Inspection....................................................................................................................................................................................... 994 Center Ventilation Louver Removal and Installation........................................................................................................................................................................... 994 Side Ventilation Louver Removal and Installation............................................................................................................................................................................. 995 HVAC Air Filter Removal and Installation (If Equipped)....................................................................................................................................................................... 996 HVAC Air Filter Inspection (If Equipped)..................................................................................................................................................................................... 996 Air Conditioning System.............................................................................................................................................................................................................. 997 Manual Type...................................................................................................................................................................................................................... 997 Precautions.................................................................................................................................................................................................................. 997 A/C System Caution....................................................................................................................................................................................................... 997 Precautions on Servicing A/C System...................................................................................................................................................................................... 997 General Description.......................................................................................................................................................................................................... 999 Refrigerant Type Identification.......................................................................................................................................................................................... 999 Compressor Type Identification........................................................................................................................................................................................... 999 Sub-Cool A/C System Description..........................................................................................................................................................................................1000 A/C Operation Description................................................................................................................................................................................................1001 Schematic and Routing Diagram................................................................................................................................................................................................1001 Major Components of A/C System...........................................................................................................................................................................................1001 A/C System Wiring Diagram................................................................................................................................................................................................1003 Diagnostic Information and Procedures........................................................................................................................................................................................1004 A/C System Symptom Diagnosis.............................................................................................................................................................................................1004 Abnormal Noise Symptom Diagnosis of A/C System...........................................................................................................................................................................1007 A/C System Performance Inspection........................................................................................................................................................................................1009 A/C System Inspection at ECM.............................................................................................................................................................................................1013 Repair Instructions..........................................................................................................................................................................................................1014 Operation Procedure for Refrigerant Charge...............................................................................................................................................................................1014 Condenser Assembly On-Vehicle Inspection.................................................................................................................................................................................1019 Condenser Assembly Removal and Installation..............................................................................................................................................................................1019 Desiccant Removal and Installation.......................................................................................................................................................................................1020 HVAC Unit Components.....................................................................................................................................................................................................1021 HVAC Unit Removal and Installation.......................................................................................................................................................................................1022 Evaporator Inspection....................................................................................................................................................................................................1022 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation...........................................................................................................................................1023 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection.........................................................................................................................................................1023 Expansion Valve Removal and Installation.................................................................................................................................................................................1024 Expansion Valve Inspection...............................................................................................................................................................................................1024 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...............................................................................................................................................................1024 A/C Refrigerant Pressure Sensor Removal and Installation.................................................................................................................................................................1024 A/C Switch Inspection....................................................................................................................................................................................................1025 Compressor Relay Inspection..............................................................................................................................................................................................1025 Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1025 Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1026 Compressor Assembly Removal and Installation.............................................................................................................................................................................1026 Compressor Assembly Components for MITSUBISHI Make Compressor............................................................................................................................................................1027 Compressor Assembly Components for MATSUSHITADENKI Make Compressor.......................................................................................................................................................1028 Magnet Clutch Inspection for MITSUBISHI Make Compressor..................................................................................................................................................................1028 Magnet Clutch Inspection for MATSUSHITADENKI Make Compressor.............................................................................................................................................................1028 Magnet Clutch Removal and Installation for MITSUBISHI Make Compressor....................................................................................................................................................1029 Magnet Clutch Removal and Installation for MATSUSHITADENKI Make Compressor...............................................................................................................................................1030 Thermal Switch Inspection for MITSUBISHI Make Compressor.................................................................................................................................................................1032 Thermal Switch Removal and Installation for MITSUBISHI Make Compressor...................................................................................................................................................1032 Relief Valve Inspection for MITSUBISHI Make Compressor...................................................................................................................................................................1033 Relief Valve Inspection for MATSUSHITADENKI Make Compressor..............................................................................................................................................................1033 Relief Valve Removal and Installation for MITSUBISHI Make Compressor.....................................................................................................................................................1033 Relief Valve Removal and Installation for MATSUSHITADENKI Make Compressor................................................................................................................................................1034 Specifications...............................................................................................................................................................................................................1034 Tightening Torque Specifications.........................................................................................................................................................................................1034 Special Tools and Equipment..................................................................................................................................................................................................1035 Recommended Service Material.............................................................................................................................................................................................1035 Special Tool.............................................................................................................................................................................................................1035 Automatic Type...................................................................................................................................................................................................................1036 Precautions..................................................................................................................................................................................................................1036 A/C System Caution.......................................................................................................................................................................................................1036 Precautions in Diagnosing Trouble........................................................................................................................................................................................1036 Precautions on Servicing A/C System......................................................................................................................................................................................1036 General Description..........................................................................................................................................................................................................1036 Auto A/C System Description..............................................................................................................................................................................................1036 HVAC Control Module Operation Description................................................................................................................................................................................1038 Refrigerant Type Identification..........................................................................................................................................................................................1038 Compressor Type Identification...........................................................................................................................................................................................1038 Sub-Cool A/C System Description..........................................................................................................................................................................................1038 A/C Operation Description................................................................................................................................................................................................1038 On-Board Diagnostic System Description...................................................................................................................................................................................1039 Schematic and Routing Diagram................................................................................................................................................................................................1039 Major Components of A/C System...........................................................................................................................................................................................1039 A/C System Wiring Diagram................................................................................................................................................................................................1040 Diagnostic Information and Procedures........................................................................................................................................................................................1041 A/C System Symptom Diagnosis.............................................................................................................................................................................................1041 Abnormal Noise Symptom Diagnosis of A/C System...........................................................................................................................................................................1045 DTC Check................................................................................................................................................................................................................1045 DTC Clearance............................................................................................................................................................................................................1046 DTC Table................................................................................................................................................................................................................1047 Fail-Safe Table..........................................................................................................................................................................................................1048 Scan Tool Data...........................................................................................................................................................................................................1048 Air Conditioning System Check............................................................................................................................................................................................1050 Visual Inspection........................................................................................................................................................................................................1052 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction..................................................................................................................................................1052 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction..........................................................................................................................................1053 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction.................................................................................................................................................................1055 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................................................................................................1056 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction....................................................................................................................................1058 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction...................................................................................................................................................1060 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction......................................................................................................................................................1063 DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction..........................................................................................................................................................1065 DTC B1546: A/C Refrigerant Pressure Malfunction..........................................................................................................................................................................1066 DTC B1551: Serial Communication Circuit Malfunction......................................................................................................................................................................1067 DTC B1552: Serial Communication Signal Malfunction.......................................................................................................................................................................1068 DTC B1553: CAN Communication Signal Malfunction..........................................................................................................................................................................1068 DTC B1557: Vehicle Speed Sensor Signal Malfunction.......................................................................................................................................................................1069 DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction..........................................................................................................................................................1069 DTC B1562: Outside Air Temperature Sensor Signal Malfunction.............................................................................................................................................................1069 DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction............................................................................................................................................................1070 Inspection of HVAC Control Module and Its Circuit........................................................................................................................................................................1070 A/C System Performance Inspection........................................................................................................................................................................................1073 A/C System Inspection at ECM.............................................................................................................................................................................................1073 Repair Instructions..........................................................................................................................................................................................................1074 Operation Procedure for Refrigerant Charge...............................................................................................................................................................................1074 HVAC Unit Components.....................................................................................................................................................................................................1075 HVAC Unit Removal and Installation.......................................................................................................................................................................................1076 Temperature Control Actuator Removal and Installation....................................................................................................................................................................1076 Temperature Control Actuator Inspection..................................................................................................................................................................................1076 Air Flow Control Actuator Removal and Installation.......................................................................................................................................................................1077 Air Flow Control Actuator Inspection.....................................................................................................................................................................................1077 Air Intake Control Actuator Removal and Installation.....................................................................................................................................................................1078 Air Intake Control Actuator Inspection...................................................................................................................................................................................1078 Actuator Linkage Inspection..............................................................................................................................................................................................1078 Blower Motor Controller Removal and Installation.........................................................................................................................................................................1078 Blower Motor Controller Inspection.......................................................................................................................................................................................1078 HVAC Control Module Removal and Installation.............................................................................................................................................................................1079 Sunload Sensor Removal and Installation..................................................................................................................................................................................1079 Sunload Sensor Inspection................................................................................................................................................................................................1080 Outside Air Temperature Sensor Removal and Installation..................................................................................................................................................................1080 Outside Air Temperature Sensor Inspection................................................................................................................................................................................1080 Inside Air Temperature Sensor Removal and Installation...................................................................................................................................................................1080 Inside Air Temperature Sensor Inspection.................................................................................................................................................................................1080 Condenser Assembly On-Vehicle Inspection.................................................................................................................................................................................1080 Condenser Assembly Removal and Installation..............................................................................................................................................................................1080 Desiccant Removal and Installation.......................................................................................................................................................................................1080 Evaporator Inspection....................................................................................................................................................................................................1080 Evaporator Temperature Sensor Removal and Installation...................................................................................................................................................................1080 Evaporator Temperature Sensor Inspection.................................................................................................................................................................................1081 Expansion Valve Removal and Installation.................................................................................................................................................................................1081 Expansion Valve Inspection...............................................................................................................................................................................................1081 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...............................................................................................................................................................1081 A/C Refrigerant Pressure Sensor Removal and Installation.................................................................................................................................................................1081 Compressor Relay Inspection..............................................................................................................................................................................................1081 Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1081 Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1081 Compressor Assembly Removal and Installation.............................................................................................................................................................................1081 Compressor Assembly Components...........................................................................................................................................................................................1081 Magnet Clutch Removal and Installation...................................................................................................................................................................................1081 Magnet Clutch Inspection.................................................................................................................................................................................................1081 Thermal Switch Inspection................................................................................................................................................................................................1081 Thermal Switch Removal and Installation..................................................................................................................................................................................1081 Relief Valve Inspection..................................................................................................................................................................................................1081 Special Tools and Equipment..................................................................................................................................................................................................1082 Special Tool.............................................................................................................................................................................................................1082 Restraint................................................................................................................................................................................................................................1083 Precautions..........................................................................................................................................................................................................................1085 Precautions......................................................................................................................................................................................................................1085 Precautions on Restraint.....................................................................................................................................................................................................1085 Seat Belts...........................................................................................................................................................................................................................1086 Precautions......................................................................................................................................................................................................................1086 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................1086 General Description..............................................................................................................................................................................................................1086 Seat Belt Construction.......................................................................................................................................................................................................1086 Diagnostic Information and Procedures............................................................................................................................................................................................1088 Repair and Inspection Required after Accident................................................................................................................................................................................1088 Repair Instructions..............................................................................................................................................................................................................1088 Front Seat Belt Components...................................................................................................................................................................................................1088 Front Seat Belt Removal and Installation.....................................................................................................................................................................................1089 Front Seat Belt Inspection...................................................................................................................................................................................................1089 Rear Seat Belt Components....................................................................................................................................................................................................1091 Rear Seat Belt Removal and Installation......................................................................................................................................................................................1092 Rear Seat Belt Inspection....................................................................................................................................................................................................1092 Specifications...................................................................................................................................................................................................................1092 Tightening Torque Specifications.............................................................................................................................................................................................1092 Air Bag System.......................................................................................................................................................................................................................1093 Precautions......................................................................................................................................................................................................................1093 Precautions on Service and Diagnosis of Air Bag System.......................................................................................................................................................................1093 Precautions on Handling and Storage of Air Bag System Components.............................................................................................................................................................1093 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................1097 General Description..............................................................................................................................................................................................................1097 Air Bag System Construction..................................................................................................................................................................................................1097 Air Bag System Input / Output Table..........................................................................................................................................................................................1098 Schematic and Routing Diagram....................................................................................................................................................................................................1099 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................1099 Component Location...............................................................................................................................................................................................................1101 Air Bag System Components, Wiring and Connectors Location....................................................................................................................................................................1101 Diagnostic Information and Procedures............................................................................................................................................................................................1102 Air Bag Diagnostic System Check..............................................................................................................................................................................................1102 Air Bag Diagnostic System Check Flow.........................................................................................................................................................................................1102 DTC Table....................................................................................................................................................................................................................1103 DTC Check....................................................................................................................................................................................................................1104 DTC Clearance................................................................................................................................................................................................................1104 Scan Tool Data...............................................................................................................................................................................................................1105 “AIR BAG” Warning Lamp Comes ON Steady.......................................................................................................................................................................................1105 “AIR BAG” Warning Lamp Does Not Come ON......................................................................................................................................................................................1108 “AIR BAG” Warning Lamp Flashes...............................................................................................................................................................................................1109 DTC B1013: SDM fault.........................................................................................................................................................................................................1110 DTC B1014: “AIR BAG” Warning Lamp Circuit Failure............................................................................................................................................................................1110 DTC B1016: Power Source Voltage High.........................................................................................................................................................................................1111 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1113 DTC B1021: Front Air Bag Module Deployed.....................................................................................................................................................................................1115 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed................................................................................................................................................................1115 DTC B1026: Pretensioner Activated............................................................................................................................................................................................1116 DTC B1027: Reusable Number Exceeded..........................................................................................................................................................................................1117 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1117 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1122 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1127 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1132 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1137 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1141 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1145 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1149 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1153 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1156 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1159 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1161 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.........................................................................................................................................1163 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low..........................................................................................................................................1167 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.........................................................................................................................................1171 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit..................................................................................................................................1174 DTC B1071: Forward-Sensor Performance Problem................................................................................................................................................................................1177 DTC B1072: Forward-Sensor Communication Error................................................................................................................................................................................1177 DTC B1073: Forward-Sensor Circuit Short to Ground............................................................................................................................................................................1177 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open.............................................................................................................................................................1179 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem........................................................................................................................................................1181 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error........................................................................................................................................................1181 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground....................................................................................................................................................1181 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open.....................................................................................................................................1183 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID............................................................................................................................................................1185 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High.................................................................................................................................1185 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low..................................................................................................................................1187 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground.................................................................................................................................1189 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit..........................................................................................................................1191 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1194 Repair and Inspection Required after Accident................................................................................................................................................................................1195 Repair Instructions..............................................................................................................................................................................................................1198 Disabling Air Bag System.....................................................................................................................................................................................................1198 Enabling Air Bag System......................................................................................................................................................................................................1199 SDM Removal and Installation.................................................................................................................................................................................................1200 SDM Inspection...............................................................................................................................................................................................................1201 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1201 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1202 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1203 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1204 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1205 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1206 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1207 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1208 Forward-Sensor Removal and Installation......................................................................................................................................................................................1208 Forward-Sensor Inspection....................................................................................................................................................................................................1209 Side-Sensor Removal and Installation.........................................................................................................................................................................................1209 Side-Sensor Inspection.......................................................................................................................................................................................................1210 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................................................................................................1211 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1212 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1222 Specifications...................................................................................................................................................................................................................1223 Tightening Torque Specifications.............................................................................................................................................................................................1223 Special Tools and Equipment......................................................................................................................................................................................................1223 Use of Special Tools.........................................................................................................................................................................................................1223 Recommended Service Material.................................................................................................................................................................................................1225 Special Tool.................................................................................................................................................................................................................1225 Body, Cab and Accessories................................................................................................................................................................................................................1227 Precautions..........................................................................................................................................................................................................................1231 Precautions......................................................................................................................................................................................................................1231 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1231 Precautions for Body Service.................................................................................................................................................................................................1231 Fastener Caution for Body Service............................................................................................................................................................................................1231 Wiring Systems.......................................................................................................................................................................................................................1232 Precautions......................................................................................................................................................................................................................1232 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1232 Precautions for Wiring System................................................................................................................................................................................................1232 General Description..............................................................................................................................................................................................................1233 Abbreviations................................................................................................................................................................................................................1233 Wire / Connector Color Symbols...............................................................................................................................................................................................1233 Symbols and Marks............................................................................................................................................................................................................1234 How to Read Connector Layout Diagram.........................................................................................................................................................................................1236 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1237 How to Read Ground Point.....................................................................................................................................................................................................1239 How to Read Power Supply Diagram.............................................................................................................................................................................................1240 How to Read System Circuit Diagram...........................................................................................................................................................................................1240 Connector Layout Diagram.........................................................................................................................................................................................................1242 Connector Layout Diagram.....................................................................................................................................................................................................1242 Engine Compartment...........................................................................................................................................................................................................1242 Instrument Panel.............................................................................................................................................................................................................1246 Door, Roof...................................................................................................................................................................................................................1250 Floor........................................................................................................................................................................................................................1252 Rear.........................................................................................................................................................................................................................1256 Ground Point.....................................................................................................................................................................................................................1257 Ground (earth) Point.........................................................................................................................................................................................................1257 Power Supply Diagram.............................................................................................................................................................................................................1258 Power Supply Diagram.........................................................................................................................................................................................................1258 Fuses and the Protected Parts................................................................................................................................................................................................1260 Fuses in Main Fuse Box (RHD).................................................................................................................................................................................................1260 Fuses in Main Fuse Box (LHD).................................................................................................................................................................................................1260 Individual Circuit Fuse Box No. 1............................................................................................................................................................................................1261 Individual Circuit Fuse Box No. 2 (In J/B)...................................................................................................................................................................................1262 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1264 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1266 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1267 System Circuit Diagram...........................................................................................................................................................................................................1272 System Circuit Diagram.......................................................................................................................................................................................................1272 A-1 Cranking System Circuit Diagram..........................................................................................................................................................................................1273 A-2 Charging System Circuit Diagram..........................................................................................................................................................................................1274 A-3 Ignition System Circuit Diagram..........................................................................................................................................................................................1275 A-4 Cooling System Circuit Diagram...........................................................................................................................................................................................1276 A-5 Engine and A/C Control System Circuit Diagram............................................................................................................................................................................1277 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1282 A-7 Immobilizer System Circuit Diagram.......................................................................................................................................................................................1284 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1285 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1289 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1290 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1291 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1292 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1294 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1296 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1297 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1298 B-9 Keyless Start System Circuit Diagram.....................................................................................................................................................................................1299 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................................................................................................1300 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................................................................................................1301 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................................................................................................1302 D-1 Headlight System Circuit Diagram.........................................................................................................................................................................................1304 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1306 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1307 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1308 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1309 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1310 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1312 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1313 D-9 Headlight Beam Leveling System Circuit Diagram...........................................................................................................................................................................1314 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1315 E-1 Heater System Circuit Diagram............................................................................................................................................................................................1316 E-2 Auto A/C System Circuit Diagram..........................................................................................................................................................................................1318 F-1 Air-Bag System Circuit Diagram...........................................................................................................................................................................................1320 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1322 F-3 Power Steering System Circuit Diagram....................................................................................................................................................................................1324 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1326 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1327 List of Connector................................................................................................................................................................................................................1328 List of Connectors...........................................................................................................................................................................................................1328 C Connector..................................................................................................................................................................................................................1328 E Connector..................................................................................................................................................................................................................1329 G Connector..................................................................................................................................................................................................................1331 J Connector..................................................................................................................................................................................................................1332 K Connector..................................................................................................................................................................................................................1333 L Connector..................................................................................................................................................................................................................1333 O Connector..................................................................................................................................................................................................................1335 R Connector..................................................................................................................................................................................................................1335 Lighting Systems.....................................................................................................................................................................................................................1336 Component Location...............................................................................................................................................................................................................1336 Lighting System Components Location..........................................................................................................................................................................................1336 Interior Light System Location...............................................................................................................................................................................................1337 Diagnostic Information and Procedures............................................................................................................................................................................................1337 Headlight Symptom Diagnosis..................................................................................................................................................................................................1337 DRL System Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1337 Headlight Leveling System Symptom Diagnosis (If Equipped)....................................................................................................................................................................1338 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1338 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1339 Back-Up Light Symptom Diagnosis..............................................................................................................................................................................................1339 Brake Light Symptom Diagnosis................................................................................................................................................................................................1339 Front Fog Light Symptom Diagnosis (If Equipped)..............................................................................................................................................................................1339 Rear Fog Light Symptom Diagnosis (If Equipped)...............................................................................................................................................................................1340 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1340 DRL Operation Inspection (If Equipped).......................................................................................................................................................................................1340 Inspection of DRL Controller and Its Circuits (If Equipped)..................................................................................................................................................................1341 Repair Instructions..............................................................................................................................................................................................................1342 Headlight Housing Removal and Installation...................................................................................................................................................................................1342 Headlight Bulb Replacement...................................................................................................................................................................................................1342 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1343 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1344 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1344 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1345 Hazard Warning Switch Inspection.............................................................................................................................................................................................1345 Brake Light Switch Inspection................................................................................................................................................................................................1346 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1346 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1346 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1346 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1346 License Lamp Assembly Removal and Installation...............................................................................................................................................................................1347 Front Fog Light Assembly Removal and Installation (If Equipped)..............................................................................................................................................................1347 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1348 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1348 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1348 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1349 Headlight Leveling Switch Inspection (If Equipped)...........................................................................................................................................................................1350 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................................................................................................1350 Rear Fog Light Switch Inspection (If Equipped)...............................................................................................................................................................................1350 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1351 Precautions......................................................................................................................................................................................................................1351 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................................................................................................1351 General Description..............................................................................................................................................................................................................1351 CAN Communication Data of Combination Meter..................................................................................................................................................................................1351 Auto Volume Control System Description (If Equipped).........................................................................................................................................................................1352 Schematic and Routing Diagram....................................................................................................................................................................................................1353 Combination Meter Circuit Diagram............................................................................................................................................................................................1353 Component Location...............................................................................................................................................................................................................1354 Audio System Component Location..............................................................................................................................................................................................1354 Diagnostic Information and Procedures............................................................................................................................................................................................1355 Speedometer and VSS Symptom Diagnosis........................................................................................................................................................................................1355 Tachometer Symptom Diagnosis.................................................................................................................................................................................................1355 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1355 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1355 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1356 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1356 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1357 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1357 A/T Shift Position Indicator Symptom Diagnosis (A/T Model Only)..............................................................................................................................................................1357 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1358 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1358 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1358 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1359 Horn Symptom Diagnosis.......................................................................................................................................................................................................1359 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1359 Clock Symptom Diagnosis (If Equipped)........................................................................................................................................................................................1360 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1360 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1362 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1362 Repair Instructions..............................................................................................................................................................................................................1362 Ignition Switch Removal and Installation.....................................................................................................................................................................................1362 Ignition Switch Inspection...................................................................................................................................................................................................1363 Combination Meter Removal and Installation...................................................................................................................................................................................1363 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1364 Fuel Level Sensor Inspection.................................................................................................................................................................................................1364 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1364 Oil Pressure Switch Inspection...............................................................................................................................................................................................1365 VSS Removal and Installation.................................................................................................................................................................................................1365 VSS Inspection...............................................................................................................................................................................................................1365 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1365 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1365 Parking Brake Switch Inspection..............................................................................................................................................................................................1365 Door Switch (Front / Rear Door) Inspection...................................................................................................................................................................................1366 Rear End Door Switch Inspection..............................................................................................................................................................................................1366 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1366 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1366 Instrument Panel Removal and Installation....................................................................................................................................................................................1367 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1368 Audio Unit Removal and Installation..........................................................................................................................................................................................1368 Front Speaker Removal and Installation.......................................................................................................................................................................................1368 Rear Speaker Removal and Installation........................................................................................................................................................................................1369 GPS Antenna Removal and Installation (If Equipped)...........................................................................................................................................................................1369 Horn Removal and Installation................................................................................................................................................................................................1369 Horn Inspection..............................................................................................................................................................................................................1369 Horn Relay Inspection........................................................................................................................................................................................................1370 Antenna Amplifier Removal and Installation...................................................................................................................................................................................1370 Remote Audio Control Switch Inspection (If Equipped).........................................................................................................................................................................1371 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...............................................................................................................................................................1371 Specifications...................................................................................................................................................................................................................1372 Tightening Torque Specifications.............................................................................................................................................................................................1372 Wipers / Washers.....................................................................................................................................................................................................................1373 Diagnostic Information and Procedures............................................................................................................................................................................................1373 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1373 Rear Wiper and Washer Symptom Diagnosis......................................................................................................................................................................................1373 Repair Instructions..............................................................................................................................................................................................................1374 Wipers and Washers Components................................................................................................................................................................................................1374 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1375 Washer Pump Inspection.......................................................................................................................................................................................................1375 Windshield Wiper Removal and Installation....................................................................................................................................................................................1376 Windshield Wiper Motor Inspection............................................................................................................................................................................................1376 Rear Wiper Removal and Installation..........................................................................................................................................................................................1377 Rear Wiper Motor Inspection..................................................................................................................................................................................................1378 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1379 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1379 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1380 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1381 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1381 Rear Wiper Relay Inspection..................................................................................................................................................................................................1381 Specifications...................................................................................................................................................................................................................1381 Tightening Torque Specifications.............................................................................................................................................................................................1381 Glass / Windows / Mirrors............................................................................................................................................................................................................1382 General Description..............................................................................................................................................................................................................1382 Rear End Door Window Defogger System Description.............................................................................................................................................................................1382 Windshield Construction......................................................................................................................................................................................................1382 Diagnostic Information and Procedures............................................................................................................................................................................................1383 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1383 Power Window Control System Symptom Diagnosis................................................................................................................................................................................1383 Power Door Mirror Control System Symptom Diagnosis...........................................................................................................................................................................1384 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1384 Repair Instructions..............................................................................................................................................................................................................1384 Windshield Removal and Installation..........................................................................................................................................................................................1384 Front Door Window Components.................................................................................................................................................................................................1388 Front Door Glass Removal and Installation....................................................................................................................................................................................1388 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1389 Front Door Window Regulator Inspection.......................................................................................................................................................................................1390 Rear Door Window Components..................................................................................................................................................................................................1390 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1391 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1392 Rear Door Window Regulator Inspection........................................................................................................................................................................................1392 Rear End Door Window Components..............................................................................................................................................................................................1393 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1393 Rear End Door Window Defogger Switch Inspection..............................................................................................................................................................................1394 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1394 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1394 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1395 Power Window Main Switch Inspection..........................................................................................................................................................................................1395 Power Window Sub Switch Inspection...........................................................................................................................................................................................1397 Door Mirror Components.......................................................................................................................................................................................................1397 Door Mirror Removal and Installation.........................................................................................................................................................................................1398 Power Door Mirror Switch Inspection..........................................................................................................................................................................................1398 Power Door Mirror Actuator Inspection........................................................................................................................................................................................1398 Door Mirror Heater Switch Inspection (If Equipped)...........................................................................................................................................................................1399 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1399 Special Tools and Equipment......................................................................................................................................................................................................1399 Recommended Service Material.................................................................................................................................................................................................1399 Security and Locks...................................................................................................................................................................................................................1400 General Description..............................................................................................................................................................................................................1400 Key Coding Construction......................................................................................................................................................................................................1400 Rear End Door Opener System Description......................................................................................................................................................................................1400 Component Location...............................................................................................................................................................................................................1401 Power Door Lock and Keyless Entry System Component Location..................................................................................................................................................................1401 Diagnostic Information and Procedures............................................................................................................................................................................................1402 Power Door Lock System Symptom Diagnosis.....................................................................................................................................................................................1402 Power Door Lock System Operation Inspection..................................................................................................................................................................................1402 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1403 Keyless Entry System Operation Inspection....................................................................................................................................................................................1404 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1404 Rear End Door Opener System Symptom Diagnosis................................................................................................................................................................................1404 Rear End Door Opener System Operation Inspection.............................................................................................................................................................................1404 Repair Instructions..............................................................................................................................................................................................................1405 Front Door Lock Assembly Components..........................................................................................................................................................................................1405 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1406 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1407 Power Door Lock Switch Inspection............................................................................................................................................................................................1407 Door Key Cylinder Switch Inspection..........................................................................................................................................................................................1408 Power Door Lock Actuator Inspection..........................................................................................................................................................................................1408 Rear Door Lock Assembly Components...........................................................................................................................................................................................1409 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1409 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1409 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1410 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1411 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1411 Rear End Door Opener Switch Inspection.......................................................................................................................................................................................1411 Replacement of Transmitter Battery...........................................................................................................................................................................................1412 Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System).................................................................................................................................1412 Keyless Entry Answer Back Function Change- over Procedure (If Equipped)......................................................................................................................................................1413 Keyless Entry Receiver Removal and Installation..............................................................................................................................................................................1413 Keyless Entry Receiver and Its Circuit Inspection............................................................................................................................................................................1414 Specifications...................................................................................................................................................................................................................1415 Tightening Torque Specifications.............................................................................................................................................................................................1415 Special Tools and Equipment......................................................................................................................................................................................................1415 Recommended Service Material.................................................................................................................................................................................................1415 Seats................................................................................................................................................................................................................................1416 Diagnostic Information and Procedures............................................................................................................................................................................................1416 Front Seat Heater Symptom Diagnosis (If Equipped)............................................................................................................................................................................1416 Repair Instructions..............................................................................................................................................................................................................1416 Front Seat Components........................................................................................................................................................................................................1416 Front Seat Removal and Installation..........................................................................................................................................................................................1417 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)................................................................................................................................................1417 Front Seat Heater Wire Inspection (If Equipped)..............................................................................................................................................................................1417 Rear Seat Components.........................................................................................................................................................................................................1418 Rear Seat Removal and Installation...........................................................................................................................................................................................1418 Specifications...................................................................................................................................................................................................................1418 Tightening Torque Specifications.............................................................................................................................................................................................1418 Interior Trim........................................................................................................................................................................................................................1419 Repair Instructions..............................................................................................................................................................................................................1419 Floor Carpet Removal and Installation........................................................................................................................................................................................1419 Head Lining Removal and Installation.........................................................................................................................................................................................1419 Console Box Components.......................................................................................................................................................................................................1420 Roof Molding Components......................................................................................................................................................................................................1421 Splash Guard (If Equipped) Components........................................................................................................................................................................................1421 Specifications...................................................................................................................................................................................................................1422 Tightening Torque Specifications.............................................................................................................................................................................................1422 Hood / Fenders / Doors...............................................................................................................................................................................................................1423 Repair Instructions..............................................................................................................................................................................................................1423 Hood Removal and Installation................................................................................................................................................................................................1423 Hood Inspection and Adjustment...............................................................................................................................................................................................1423 Front Fender Components......................................................................................................................................................................................................1424 Front Fender Removal and Installation........................................................................................................................................................................................1424 Front Door Assembly Components...............................................................................................................................................................................................1425 Front Door Assembly Removal and Installation.................................................................................................................................................................................1425 Rear Door Assembly Components................................................................................................................................................................................................1426 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1427 Rear End Door Assembly Components............................................................................................................................................................................................1427 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1427 Specifications...................................................................................................................................................................................................................1429 Tightening Torque Specifications.............................................................................................................................................................................................1429 Special Tools and Equipment......................................................................................................................................................................................................1429 Recommended Service Material.................................................................................................................................................................................................1429 Body Structure.......................................................................................................................................................................................................................1430 Repair Instructions..............................................................................................................................................................................................................1430 Front Bumper and Rear Bumper Components......................................................................................................................................................................................1430 Cowl Top Components..........................................................................................................................................................................................................1431 Specifications...................................................................................................................................................................................................................1432 Body Dimensions..............................................................................................................................................................................................................1432 Panel Clearance..............................................................................................................................................................................................................1439 Paint / Coatings.....................................................................................................................................................................................................................1440 General Description..............................................................................................................................................................................................................1440 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1440 Plastic Parts Finishing......................................................................................................................................................................................................1440 Component Location...............................................................................................................................................................................................................1441 Sealant Application Areas....................................................................................................................................................................................................1441 Under Coating Application Areas..............................................................................................................................................................................................1446 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1448 Exterior Trim........................................................................................................................................................................................................................1449 Repair Instructions..............................................................................................................................................................................................................1449 Roof Molding Components......................................................................................................................................................................................................1449 Splash Guard (If Equipped) Components........................................................................................................................................................................................1450 Control Systems..........................................................................................................................................................................................................................1451 Precautions..........................................................................................................................................................................................................................1453 Precautions......................................................................................................................................................................................................................1453 Precautions for Control Systems..............................................................................................................................................................................................1453 Body Electrical Control System.......................................................................................................................................................................................................1454 Precautions......................................................................................................................................................................................................................1454 Precautions in Diagnosing Trouble............................................................................................................................................................................................1454 General Description..............................................................................................................................................................................................................1454 BCM General Description......................................................................................................................................................................................................1454 CAN Communication System Description.........................................................................................................................................................................................1455 Theft Deterrent Light........................................................................................................................................................................................................1455 Security Alarm Description (If Equipped).....................................................................................................................................................................................1456 Schematic and Routing Diagram....................................................................................................................................................................................................1457 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1457 Connector Layout Diagram of BCM and Junction Block Assembly..................................................................................................................................................................1460 Component Location...............................................................................................................................................................................................................1461 BCM and Related System Component Location....................................................................................................................................................................................1461 Diagnostic Information and Procedures............................................................................................................................................................................................1462 BCM Self-Diagnosis Function..................................................................................................................................................................................................1462 Body Electrical Control System Check.........................................................................................................................................................................................1463 Scan Tool Data...............................................................................................................................................................................................................1465 DTC Table....................................................................................................................................................................................................................1467 DTC Check....................................................................................................................................................................................................................1468 DTC Clearance................................................................................................................................................................................................................1470 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1470 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1472 DTC B1141 / DTC B1142 / DTC B1143 (No. 1141 / No. 1142/ No. 1143): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction........................................................................................1473 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1474 DTC B1157 (No. 1157): Air Bag Deployment Signal Input........................................................................................................................................................................1476 DTC B1170 (No. 1170): EEPROM Access Error....................................................................................................................................................................................1476 DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error)......................................................................................................................................................1477 DTC U1073 (No. 1073): Control Module Communication Bus Off...................................................................................................................................................................1479 DTC U1100 (No. 1100): Lost Communication with ECM............................................................................................................................................................................1481 DTC U1101 (No. 1101): Lost Communication with TCM............................................................................................................................................................................1482 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1484 Inspection of BCM and its Circuits...........................................................................................................................................................................................1486 Repair Instructions..............................................................................................................................................................................................................1494 BCM (Included in Junction Block Assembly) Removal and Installation...........................................................................................................................................................1494 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1494 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1494 Security Alarm Mode Selection Procedure (If Equipped)........................................................................................................................................................................1495 Special Tools and Equipment......................................................................................................................................................................................................1495 Special Tool.................................................................................................................................................................................................................1495 Immobilizer Control System...........................................................................................................................................................................................................1496 Precautions......................................................................................................................................................................................................................1496 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1496 Precaution in Replacing ECM..................................................................................................................................................................................................1496 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1496 General Description..............................................................................................................................................................................................................1497 Immobilizer Control System Introduction......................................................................................................................................................................................1497 Immobilizer Control System Components Location...............................................................................................................................................................................1498 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................................................................................................1498 Schematic and Routing Diagram....................................................................................................................................................................................................1499 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1499 Diagnostic Information and Procedures............................................................................................................................................................................................1500 Immobilizer Control System Check.............................................................................................................................................................................................1500 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1501 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1501 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1501 Scan Tool Data...............................................................................................................................................................................................................1502 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1502 Immobilizer Indicator Lamp Remains ON after Engine Starts....................................................................................................................................................................1503 DTC P1614: Transponder Response Error........................................................................................................................................................................................1504 DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only).....................................................................................................................................1505 DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only).................................................................................................................................1506 DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)......................................................................................1507 DTC P1621: Immobilizer Communication Line Error..............................................................................................................................................................................1508 DTC P1622: EEPROM Reading / Writing Error....................................................................................................................................................................................1509 DTC P1623: Unregistered Transponder..........................................................................................................................................................................................1509 DTC P1625: Immobilizer Antenna Error.........................................................................................................................................................................................1510 DTC P1636: Immobilizer Information Registration Failure......................................................................................................................................................................1510 DTC P1638: Immobilizer Information Mismatched................................................................................................................................................................................1511 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1512 Repair Instructions..............................................................................................................................................................................................................1514 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1514 Registration of the Ignition Key.............................................................................................................................................................................................1514 Procedure after ECM Replacement..............................................................................................................................................................................................1514 Special Tools and Equipment......................................................................................................................................................................................................1515 Special Tool.................................................................................................................................................................................................................1515 Keyless Start System.................................................................................................................................................................................................................1516 General Description..............................................................................................................................................................................................................1516 Keyless Start System Description.............................................................................................................................................................................................1516 Parts and Functions..........................................................................................................................................................................................................1517 Keyless Engine Start Function................................................................................................................................................................................................1518 Door Lock Function of Keyless Start System...................................................................................................................................................................................1519 Operation Area of Remote Controller..........................................................................................................................................................................................1520 Alarm Function...............................................................................................................................................................................................................1521 CAN Communication of Keyless Start System....................................................................................................................................................................................1521 Schematic and Routing Diagram....................................................................................................................................................................................................1522 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1522 Diagnostic Information and Procedures............................................................................................................................................................................................1523 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1523 Self-Diagnosis Function......................................................................................................................................................................................................1523 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1523 Keyless Start System Check...................................................................................................................................................................................................1523 Customer Questionnaire (Example).............................................................................................................................................................................................1524 Key Indicator Lamp Check.....................................................................................................................................................................................................1525 DTC Check....................................................................................................................................................................................................................1525 DTC Table....................................................................................................................................................................................................................1526 DTC Clearance................................................................................................................................................................................................................1527 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1528 Keyless Start System Operation Inspection....................................................................................................................................................................................1529 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1529 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1530 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1534 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.).....................................................................................................................1535 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1537 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1538 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1539 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)..........................................................................................................1539 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1540 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1542 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1544 Repair Instructions..............................................................................................................................................................................................................1546 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1546 Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection..............................................................................................................................................1547 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1547 Steering Lock Unit Inspection................................................................................................................................................................................................1547 Front Door Lock Switch Inspection............................................................................................................................................................................................1547 Keyless Start Control Module Removal and Installation........................................................................................................................................................................1548 Remote Controller Inspection.................................................................................................................................................................................................1548 Replacement of Remote Controller Battery.....................................................................................................................................................................................1548 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1549 COPYRIGHT................................................................................................................................................................................................................................1551 BOOKCOVER_VOL1...........................................................................................................................................................................................................................1552 BOOKCOVER_VOL2...........................................................................................................................................................................................................................1553
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