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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 : 1521
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
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........................................................................................................................................................................................ 13 Warning for Handling Emergency Flat Tire Repair Kit.......................................................................................................................................................................... 13 Precautions in Servicing Full-Time 4WD Vehicle............................................................................................................................................................................... 14 Precautions for Catalytic Converter.......................................................................................................................................................................................... 14 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 14 Precaution for CAN Communication System...................................................................................................................................................................................... 15 Precautions for Electrical Circuit Service................................................................................................................................................................................... 15 Air Bag Warning.............................................................................................................................................................................................................. 17 Air Bag System Service Warning............................................................................................................................................................................................... 17 Fastener Caution............................................................................................................................................................................................................. 17 Suspension Caution........................................................................................................................................................................................................... 17 Wheels and Tires Caution..................................................................................................................................................................................................... 17 Brake Caution................................................................................................................................................................................................................ 18 Repair Instructions.............................................................................................................................................................................................................. 18 Electrical Circuit Inspection Procedure...................................................................................................................................................................................... 18 Intermittent and Poor Connection Inspection.................................................................................................................................................................................. 20 General Information...................................................................................................................................................................................................................... 23 General Information.................................................................................................................................................................................................................. 24 General Description.............................................................................................................................................................................................................. 24 Abbreviations................................................................................................................................................................................................................ 24 Symbols...................................................................................................................................................................................................................... 25 Wire Color Symbols........................................................................................................................................................................................................... 25 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.............................................................................................................................................................................................................. 36 Accessory Drive Belt Inspection.............................................................................................................................................................................................. 36 Accessory Drive Belt Replacement............................................................................................................................................................................................. 36 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 36 Engine Oil and Filter Change................................................................................................................................................................................................. 37 Engine Coolant Change........................................................................................................................................................................................................ 38 Exhaust System Inspection.................................................................................................................................................................................................... 38 Spark Plug Replacement....................................................................................................................................................................................................... 39 Air Cleaner Filter Inspection................................................................................................................................................................................................ 39 Air Cleaner Filter Replacement............................................................................................................................................................................................... 39 Fuel Lines and Connections Inspection........................................................................................................................................................................................ 39 Fuel Filter Replacement...................................................................................................................................................................................................... 39 Fuel Tank Inspection......................................................................................................................................................................................................... 39 PCV Valve Inspection......................................................................................................................................................................................................... 39 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 40 Brake Discs and Pads (Front) Inspection...................................................................................................................................................................................... 40 Brake Drums and Shoes (Rear) Inspection...................................................................................................................................................................................... 40 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 40 Brake Fluid Replacement...................................................................................................................................................................................................... 41 Brake Lever and Cable Inspection............................................................................................................................................................................................. 41 Clutch Fluid Inspection...................................................................................................................................................................................................... 41 Tires Inspection............................................................................................................................................................................................................. 41 Wheel Discs Inspection....................................................................................................................................................................................................... 42 Wheel Bearing Inspection..................................................................................................................................................................................................... 42 Suspension System Inspection................................................................................................................................................................................................. 42 Steering System Inspection................................................................................................................................................................................................... 42 Drive Shaft (Axle) Boots Inspection.......................................................................................................................................................................................... 43 Propeller Shafts (4WD) Inspection............................................................................................................................................................................................ 43 Manual Transaxle Oil Inspection.............................................................................................................................................................................................. 43 Manual Transaxle Oil Replacement............................................................................................................................................................................................. 43 Automatic Transaxle Fluid Level Inspection................................................................................................................................................................................... 44 Automatic Transaxle Fluid Replacement........................................................................................................................................................................................ 44 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............................................................................................................................................................... 45 All Latches, Hinges and Locks Inspection..................................................................................................................................................................................... 45 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 Precaution on On-Board Diagnostic (OBD) System............................................................................................................................................................................... 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......................................................................................................................................................................................... 57 On-Board Diagnostic System Description....................................................................................................................................................................................... 57 Data Link Connector (DLC).................................................................................................................................................................................................... 60 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).................................................................................................................................... 62 Electronic Control System Description........................................................................................................................................................................................ 63 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 69 Schematic and Routing Diagram.................................................................................................................................................................................................... 70 Engine and Emission Control System Diagram................................................................................................................................................................................... 70 Component Location............................................................................................................................................................................................................... 71 Electronic Control System Components Location................................................................................................................................................................................ 71 Diagnostic Information and Procedures............................................................................................................................................................................................ 72 Engine and Emission Control System Check..................................................................................................................................................................................... 72 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 75 DTC Check.................................................................................................................................................................................................................... 76 DTC Clearance................................................................................................................................................................................................................ 77 DTC Table.................................................................................................................................................................................................................... 77 Fail-Safe Table.............................................................................................................................................................................................................. 83 Scan Tool Data............................................................................................................................................................................................................... 83 Visual Inspection............................................................................................................................................................................................................ 88 Engine Basic Inspection...................................................................................................................................................................................................... 88 Engine Symptom Diagnosis..................................................................................................................................................................................................... 91 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started).............................................................................................................. 97 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 99 DTC P0010: Camshaft Position Actuator Circuit (For Engine with VVT).......................................................................................................................................................... 101 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For Engine with VVT).......................................................................................................... 103 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 105 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 107 DTC P0101: Mass Air Flow Circuit Range / Performance......................................................................................................................................................................... 109 DTC P0102: Mass Air Flow Circuit Low Input................................................................................................................................................................................... 113 DTC P0103: Mass Air Flow Circuit High Input.................................................................................................................................................................................. 115 DTC P0106: Manifold Absolute Pressure Range / Performance.................................................................................................................................................................... 117 DTC P0107: Manifold Absolute Pressure Circuit Low Input...................................................................................................................................................................... 119 DTC P0108: Manifold Absolute Pressure Circuit High Input..................................................................................................................................................................... 121 DTC P0111: Intake Air Temperature Circuit Range / Performance................................................................................................................................................................ 123 DTC P0112: Intake Air Temperature Sensor Circuit Low......................................................................................................................................................................... 127 DTC P0113: Intake Air Temperature Sensor Circuit High........................................................................................................................................................................ 129 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 132 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 135 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 137 DTC P0121: Throttle Position Sensor Circuit Range / Performance.............................................................................................................................................................. 139 DTC P0122: Throttle Position Sensor Circuit Low.............................................................................................................................................................................. 144 DTC P0123: Throttle Position Sensor Circuit High............................................................................................................................................................................. 146 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................................................................................................ 149 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 152 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).......................................................................................................................................................... 153 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 156 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 159 DTC P0171 / P0172: Fuel System Too Lean / Rich............................................................................................................................................................................... 161 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...................................................................................... 163 DTC P0327 / P0328: Knock Sensor Circuit Low / High........................................................................................................................................................................... 165 DTC P0335: Crankshaft Position (CKP) Sensor Circuit.......................................................................................................................................................................... 167 DTC P0340: Camshaft Position (CMP) Sensor Circuit............................................................................................................................................................................ 169 DTC P0350: Ignition Coil Primary / Secondary Circuit......................................................................................................................................................................... 172 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 174 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 177 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 179 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 181 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 183 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction............................................................................................................................................................................ 188 DTC P0505: Idle Air Control System........................................................................................................................................................................................... 191 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low....................................................................................................................................................................... 193 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...................................................................................................................................................................... 195 DTC P0601 / P0602: Internal Control Module Memory Check Sum Error / Control Module Programming Error......................................................................................................................... 198 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 199 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 201 DTC P0620: Generator Control Circuit......................................................................................................................................................................................... 203 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High............................................................................................................................................................... 205 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High........................................................................................................................................................... 207 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 209 DTC P1603: TCM Trouble Code Detected......................................................................................................................................................................................... 210 DTC P1674: CAN Communication (Bus Off Error)................................................................................................................................................................................. 211 DTC P1676: CAN Communication (Reception Error for TCM)....................................................................................................................................................................... 216 DTC P1678: CAN Communication (Reception Error for BCM)....................................................................................................................................................................... 219 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 222 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 223 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 245 Fuel Injector Circuit Check.................................................................................................................................................................................................. 248 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 250 Fuel Pressure Check.......................................................................................................................................................................................................... 253 Idle Air Control System Check................................................................................................................................................................................................ 254 A/C System Circuits Check.................................................................................................................................................................................................... 256 Electric Load Signal Circuit Check........................................................................................................................................................................................... 260 Radiator Cooling Fan Low Speed Control System Check.......................................................................................................................................................................... 262 Radiator Cooling Fan High Speed Control System Check......................................................................................................................................................................... 264 Repair Instructions.............................................................................................................................................................................................................. 267 Idle Speed / Idle Air Control (IAC) Duty Inspection.......................................................................................................................................................................... 267 Special Tools and Equipment...................................................................................................................................................................................................... 268 Special Tool................................................................................................................................................................................................................. 268 Aux. Emission Control Devices........................................................................................................................................................................................................ 269 Diagnostic Information and Procedures............................................................................................................................................................................................ 269 EGR System Inspection........................................................................................................................................................................................................ 269 Repair Instructions.............................................................................................................................................................................................................. 269 EVAP Canister Purge Inspection............................................................................................................................................................................................... 269 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 270 Vacuum Passage Inspection.................................................................................................................................................................................................... 271 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................................................................................................... 271 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 271 EVAP Canister Inspection..................................................................................................................................................................................................... 272 EGR Valve Removal and Installation........................................................................................................................................................................................... 272 EGR Valve Inspection......................................................................................................................................................................................................... 272 PCV Hose Inspection.......................................................................................................................................................................................................... 273 PCV Valve Inspection......................................................................................................................................................................................................... 273 Special Tools and Equipment...................................................................................................................................................................................................... 273 Special Tool................................................................................................................................................................................................................. 273 Engine Electrical Devices............................................................................................................................................................................................................ 274 Repair Instructions.............................................................................................................................................................................................................. 274 Idle Air Control (IAC) Valve Operation Inspection............................................................................................................................................................................ 274 Idle Air Control (IAC) Valve On-Vehicle Inspection........................................................................................................................................................................... 274 Idle Air Control (IAC) Valve Removal and Installation........................................................................................................................................................................ 274 Engine Control Module (ECM) Removal and Installation......................................................................................................................................................................... 275 Manifold Absolute Pressure (MAP) Sensor Inspection........................................................................................................................................................................... 276 Throttle Position (TP) Sensor On-Vehicle Inspection.......................................................................................................................................................................... 276 Throttle Position (TP) Sensor Removal and Installation....................................................................................................................................................................... 276 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................................................................................................................. 277 Engine Coolant Temperature (ECT) Sensor Inspection........................................................................................................................................................................... 277 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection........................................................................................................................................................ 278 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation............................................................................................................................................................ 278 Camshaft Position (CMP) Sensor Removal and Installation...................................................................................................................................................................... 278 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 279 Crankshaft Position (CKP) Sensor Removal and Installation.................................................................................................................................................................... 280 Crankshaft Position (CKP) Sensor Inspection.................................................................................................................................................................................. 280 Vehicle Speed Sensor (VSS) Inspection (M/T model)............................................................................................................................................................................ 281 Knock Sensor Removal and Installation........................................................................................................................................................................................ 281 Main Relay, Fuel Pump Relay and Starting Motor Control Relay Inspection...................................................................................................................................................... 282 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................................................................................................ 282 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation......................................................................................................................................... 283 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection....................................................................................................................................................... 283 Electric Load Current Sensor On-Vehicle Inspection (If Equipped)............................................................................................................................................................. 284 Specifications................................................................................................................................................................................................................... 285 Tightening Torque Specifications............................................................................................................................................................................................. 285 Special Tools and Equipment...................................................................................................................................................................................................... 285 Special Tool................................................................................................................................................................................................................. 285 Engine Mechanical.................................................................................................................................................................................................................... 286 General Description.............................................................................................................................................................................................................. 286 Engine Construction Description.............................................................................................................................................................................................. 286 Camshaft Position Control (VVT Variable Valve Timing) System Description..................................................................................................................................................... 288 Diagnostic Information and Procedures............................................................................................................................................................................................ 290 Compression Check............................................................................................................................................................................................................ 290 Engine Vacuum Check.......................................................................................................................................................................................................... 291 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 292 Repair Instructions.............................................................................................................................................................................................................. 295 Air Cleaner Filter Removal and Installation.................................................................................................................................................................................. 295 Air Cleaner Filter Inspection and Cleaning................................................................................................................................................................................... 295 Cylinder Head Cover Removal and Installation................................................................................................................................................................................. 295 Accelerator Cable Adjustment................................................................................................................................................................................................. 297 Throttle Body and Intake Manifold Components................................................................................................................................................................................. 298 Throttle Body On-Vehicle Inspection.......................................................................................................................................................................................... 299 Throttle Body Removal and Installation....................................................................................................................................................................................... 299 Throttle Body Cleaning....................................................................................................................................................................................................... 300 Intake Manifold Removal and Installation..................................................................................................................................................................................... 300 Engine Mountings Components.................................................................................................................................................................................................. 301 Engine Assembly Removal and Installation..................................................................................................................................................................................... 302 Timing Chain Cover Components................................................................................................................................................................................................ 306 Timing Chain Cover Removal and Installation.................................................................................................................................................................................. 307 Timing Chain Cover Inspection................................................................................................................................................................................................ 309 Oil Control Valve Removal and Installation (For Engine with VVT)............................................................................................................................................................. 310 Oil Control Valve Inspection (For Engine with VVT)........................................................................................................................................................................... 310 Timing Chain and Chain Tensioner Components.................................................................................................................................................................................. 311 Timing Chain and Chain Tensioner Removal and Installation.................................................................................................................................................................... 311 Timing Chain and Chain Tensioner Inspection.................................................................................................................................................................................. 315 Camshaft, Tappet and Shim Components......................................................................................................................................................................................... 316 Camshaft, Tappet and Shim Removal and Installation........................................................................................................................................................................... 317 Camshaft, Tappet and Shim Inspection......................................................................................................................................................................................... 320 Valves and Cylinder Head Components.......................................................................................................................................................................................... 323 Valves and Cylinder Head Removal and Installation............................................................................................................................................................................ 324 Valves and Cylinder Head Disassembly and Assembly............................................................................................................................................................................ 326 Valves and Valve Guides Inspection........................................................................................................................................................................................... 328 Cylinder Head Inspection..................................................................................................................................................................................................... 331 Valve Spring Inspection...................................................................................................................................................................................................... 332 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................................................................................................. 333 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................................................................................................ 333 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................................................................................................ 335 Cylinders, Pistons and Piston Rings Inspection............................................................................................................................................................................... 336 Piston Pins and Connecting Rods Inspection................................................................................................................................................................................... 338 Crank Pin and Connecting Rod Bearings Inspection............................................................................................................................................................................. 339 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................................................................................................... 343 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................................................................................................ 344 Crankshaft Inspection........................................................................................................................................................................................................ 347 Main Bearings Inspection..................................................................................................................................................................................................... 348 Sensor Plate Inspection...................................................................................................................................................................................................... 353 Rear Oil Seal Inspection..................................................................................................................................................................................................... 353 Flywheel Inspection.......................................................................................................................................................................................................... 354 Cylinder Block Inspection.................................................................................................................................................................................................... 354 Specifications................................................................................................................................................................................................................... 355 Tightening Torque Specifications............................................................................................................................................................................................. 355 Special Tools and Equipment...................................................................................................................................................................................................... 356 Recommended Service Material................................................................................................................................................................................................. 356 Special Tool................................................................................................................................................................................................................. 356 Engine Lubrication System............................................................................................................................................................................................................ 358 General Description.............................................................................................................................................................................................................. 358 Engine Lubrication Description............................................................................................................................................................................................... 358 Diagnostic Information and Procedures............................................................................................................................................................................................ 359 Oil Pressure Check........................................................................................................................................................................................................... 359 Repair Instructions.............................................................................................................................................................................................................. 360 Oil Pan and Oil Pump Strainer Components..................................................................................................................................................................................... 360 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................................................................................................... 361 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................................................................................................... 363 Oil Pump Components.......................................................................................................................................................................................................... 363 Oil Pump Removal and Installation............................................................................................................................................................................................ 363 Oil Pump Disassembly and Reassembly.......................................................................................................................................................................................... 363 Oil Pump Inspection.......................................................................................................................................................................................................... 364 Specifications................................................................................................................................................................................................................... 366 Tightening Torque Specifications............................................................................................................................................................................................. 366 Special Tools and Equipment...................................................................................................................................................................................................... 366 Recommended Service Material................................................................................................................................................................................................. 366 Special Tool................................................................................................................................................................................................................. 366 Engine Cooling System................................................................................................................................................................................................................ 367 General Description.............................................................................................................................................................................................................. 367 Cooling System Description................................................................................................................................................................................................... 367 Coolant Description.......................................................................................................................................................................................................... 367 Schematic and Routing Diagram.................................................................................................................................................................................................... 368 Coolant Circulation.......................................................................................................................................................................................................... 368 Diagnostic Information and Procedures............................................................................................................................................................................................ 369 Engine Cooling Symptom Diagnosis............................................................................................................................................................................................. 369 Repair Instructions.............................................................................................................................................................................................................. 370 Cooling System Components.................................................................................................................................................................................................... 370 Coolant Level Check.......................................................................................................................................................................................................... 371 Engine Cooling System Inspection and Cleaning................................................................................................................................................................................ 371 Cooling System Draining...................................................................................................................................................................................................... 371 Cooling System Flush and Refill.............................................................................................................................................................................................. 372 Cooling Water Pipes or Hoses Removal and Installation........................................................................................................................................................................ 373 Thermostat Removal and Installation.......................................................................................................................................................................................... 373 Thermostat Inspection........................................................................................................................................................................................................ 373 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................................................................................................................. 374 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 375 Radiator Cooling Fan Removal and Installation................................................................................................................................................................................ 375 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 375 Radiator Removal and Installation............................................................................................................................................................................................ 376 Water Pump Removal and Installation.......................................................................................................................................................................................... 376 Water Pump Inspection........................................................................................................................................................................................................ 377 Specifications................................................................................................................................................................................................................... 377 Tightening Torque Specifications............................................................................................................................................................................................. 377 Special Tools and Equipment...................................................................................................................................................................................................... 377 Recommended Service Material................................................................................................................................................................................................. 377 Fuel System.......................................................................................................................................................................................................................... 378 Precautions...................................................................................................................................................................................................................... 378 Precautions on Fuel System Service........................................................................................................................................................................................... 378 General Description.............................................................................................................................................................................................................. 378 Fuel System Description...................................................................................................................................................................................................... 378 Fuel Delivery System Description............................................................................................................................................................................................. 378 Fuel Pump Description........................................................................................................................................................................................................ 379 Schematic and Routing Diagram.................................................................................................................................................................................................... 379 Fuel Delivery System Diagram................................................................................................................................................................................................. 379 Diagnostic Information and Procedures............................................................................................................................................................................................ 380 Fuel Pressure Inspection..................................................................................................................................................................................................... 380 Fuel Cut Operation Inspection................................................................................................................................................................................................ 381 Repair Instructions.............................................................................................................................................................................................................. 382 Fuel System Components....................................................................................................................................................................................................... 382 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 383 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 385 Fuel Leakage Check Procedure................................................................................................................................................................................................. 385 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 385 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 385 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 386 Fuel Injector Removal and Installation....................................................................................................................................................................................... 386 Fuel Injector Inspection..................................................................................................................................................................................................... 387 Fuel Filler Cap Inspection................................................................................................................................................................................................... 388 Fuel Tank Inlet Valve Removal and Installation............................................................................................................................................................................... 389 Fuel Tank Inlet Valve Inspection............................................................................................................................................................................................. 390 Fuel Tank Removal and Installation........................................................................................................................................................................................... 390 Fuel Tank Inspection......................................................................................................................................................................................................... 391 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 392 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 392 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 392 Main Fuel Level Sensor Removal and Installation.............................................................................................................................................................................. 394 Fuel Pump Inspection......................................................................................................................................................................................................... 394 Sub Fuel Level Sensor Removal and Installation (For 4WD model)............................................................................................................................................................... 394 Sub Fuel Level Sensor Inspection (For 4WD model)............................................................................................................................................................................. 395 Specifications................................................................................................................................................................................................................... 395 Tightening Torque Specifications............................................................................................................................................................................................. 395 Special Tools and Equipment...................................................................................................................................................................................................... 396 Special Tool................................................................................................................................................................................................................. 396 Ignition System...................................................................................................................................................................................................................... 397 General Description.............................................................................................................................................................................................................. 397 Ignition System Construction................................................................................................................................................................................................. 397 Schematic and Routing Diagram.................................................................................................................................................................................................... 398 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 398 Component Location............................................................................................................................................................................................................... 399 Ignition System Components Location.......................................................................................................................................................................................... 399 Diagnostic Information and Procedures............................................................................................................................................................................................ 400 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 400 Reference Waveform of Ignition System........................................................................................................................................................................................ 400 Ignition System Check........................................................................................................................................................................................................ 400 Ignition Spark Test.......................................................................................................................................................................................................... 402 Repair Instructions.............................................................................................................................................................................................................. 402 High-Tension Cord Removal and Installation................................................................................................................................................................................... 402 High-Tension Cord Inspection................................................................................................................................................................................................. 403 Spark Plug Removal and Installation.......................................................................................................................................................................................... 403 Spark Plug Inspection........................................................................................................................................................................................................ 403 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................................................................................................... 404 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................................................................................................ 404 Ignition Timing Inspection................................................................................................................................................................................................... 404 Specifications................................................................................................................................................................................................................... 405 Tightening Torque Specifications............................................................................................................................................................................................. 405 Special Tools and Equipment...................................................................................................................................................................................................... 405 Special Tool................................................................................................................................................................................................................. 405 Starting System...................................................................................................................................................................................................................... 406 Schematic and Routing Diagram.................................................................................................................................................................................................... 406 Cranking System Circuit Diagram.............................................................................................................................................................................................. 406 Diagnostic Information and Procedures............................................................................................................................................................................................ 406 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 406 Cranking System Test......................................................................................................................................................................................................... 408 Repair Instructions.............................................................................................................................................................................................................. 409 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 409 Starting Motor Components.................................................................................................................................................................................................... 410 Starting Motor Inspection.................................................................................................................................................................................................... 411 Specifications................................................................................................................................................................................................................... 414 Cranking System Specifications............................................................................................................................................................................................... 414 Tightening Torque Specifications............................................................................................................................................................................................. 414 Special Tools and Equipment...................................................................................................................................................................................................... 414 Recommended Service Material................................................................................................................................................................................................. 414 Charging System...................................................................................................................................................................................................................... 415 General Description.............................................................................................................................................................................................................. 415 Battery Description.......................................................................................................................................................................................................... 415 Generator Description........................................................................................................................................................................................................ 417 Diagnostic Information and Procedures............................................................................................................................................................................................ 418 Battery Inspection........................................................................................................................................................................................................... 418 Generator Symptom Diagnosis.................................................................................................................................................................................................. 418 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 419 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 420 Repair Instructions.............................................................................................................................................................................................................. 420 Jump Starting in Case of Emergency........................................................................................................................................................................................... 420 Battery Dismounting and Remounting........................................................................................................................................................................................... 421 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.......................................................................................................................................................... 421 Water Pump / Generator Drive Belt Removal and Installation................................................................................................................................................................... 422 Generator Dismounting and Remounting......................................................................................................................................................................................... 423 Generator Components......................................................................................................................................................................................................... 424 Generator Inspection......................................................................................................................................................................................................... 425 Specifications................................................................................................................................................................................................................... 427 Charging System Specifications............................................................................................................................................................................................... 427 Tightening Torque Specifications............................................................................................................................................................................................. 427 Exhaust System....................................................................................................................................................................................................................... 428 General Description.............................................................................................................................................................................................................. 428 Exhaust System Description................................................................................................................................................................................................... 428 Diagnostic Information and Procedures............................................................................................................................................................................................ 428 Exhaust System Check......................................................................................................................................................................................................... 428 Repair Instructions.............................................................................................................................................................................................................. 429 Exhaust System Components.................................................................................................................................................................................................... 429 Exhaust Manifold Removal and Installation.................................................................................................................................................................................... 430 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 432 Specifications................................................................................................................................................................................................................... 432 Tightening Torque Specifications............................................................................................................................................................................................. 432 Suspension............................................................................................................................................................................................................................... 433 Precautions.......................................................................................................................................................................................................................... 435 Precautions...................................................................................................................................................................................................................... 435 Precautions on Suspension.................................................................................................................................................................................................... 435 Suspension General Diagnosis......................................................................................................................................................................................................... 436 Diagnostic Information and Procedures............................................................................................................................................................................................ 436 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 436 Front Suspension..................................................................................................................................................................................................................... 438 General Description.............................................................................................................................................................................................................. 438 Front Suspension Construction................................................................................................................................................................................................ 438 Front Wheel Alignment Construction........................................................................................................................................................................................... 439 Repair Instructions.............................................................................................................................................................................................................. 439 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 439 Front Strut Assembly Components.............................................................................................................................................................................................. 441 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 442 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 443 Front Strut Assembly Check................................................................................................................................................................................................... 445 Front Wheel Hub and Steering Knuckle Components.............................................................................................................................................................................. 445 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................................................................................................. 446 Front Wheel Hub, Disc, Nut and Bearing Check................................................................................................................................................................................. 449 Suspension Control Arm / Bushing Removal and Installation.................................................................................................................................................................... 450 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 451 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 451 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 451 Suspension Control Arm Joint Check........................................................................................................................................................................................... 452 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 452 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 453 Front Suspension Frame Check................................................................................................................................................................................................. 456 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 456 Front Suspension Fasteners Check............................................................................................................................................................................................. 456 Specifications................................................................................................................................................................................................................... 457 Tightening Torque Specifications............................................................................................................................................................................................. 457 Special Tools and Equipment...................................................................................................................................................................................................... 458 Special Tool................................................................................................................................................................................................................. 458 Rear Suspension...................................................................................................................................................................................................................... 459 General Description.............................................................................................................................................................................................................. 459 Rear Suspension Construction................................................................................................................................................................................................. 459 Component Location............................................................................................................................................................................................................... 461 Rear Suspension Component Location........................................................................................................................................................................................... 461 Repair Instructions.............................................................................................................................................................................................................. 463 Rear Wheel Alignment Inspection.............................................................................................................................................................................................. 463 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 463 Rear Shock Absorber Inspection............................................................................................................................................................................................... 464 Rear Shock Absorber Bush Removal and Installation............................................................................................................................................................................ 464 Rear Shock Absorber Bush Inspection.......................................................................................................................................................................................... 465 Coil Spring Removal and Installation......................................................................................................................................................................................... 465 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................................................................................................. 466 Spring Upper Seat and Lower Seat Removal and Installation.................................................................................................................................................................... 466 Rear Axle Removal and Installation (2WD Vehicle)............................................................................................................................................................................. 467 Rear Axle Removal and Installation (4WD Vehicle)............................................................................................................................................................................. 471 Trailing Arm, Rear Axle and Coil Spring Inspection........................................................................................................................................................................... 474 Rear Axle Bush Inspection.................................................................................................................................................................................................... 474 Wheel Bearing and Wheel Stud Bolt Removal and Installation (2WD Vehicle)..................................................................................................................................................... 474 Wheel Bearing and Wheel Stud Bolt Removal and Installation (4WD Vehicle)..................................................................................................................................................... 475 Rear Wheel Disc, Nut and Bearing Inspection.................................................................................................................................................................................. 476 Spindle Removal and Installation (2WD Vehicle)............................................................................................................................................................................... 477 Spindle Inspection........................................................................................................................................................................................................... 478 Rear Axle Flange Removal and Installation (4WD Vehicle)...................................................................................................................................................................... 478 Rear Wheel Hub and Rear Axle Flange Inspection (4WD Vehicle)................................................................................................................................................................. 479 Rear Suspension Fasteners Inspection......................................................................................................................................................................................... 479 Specifications................................................................................................................................................................................................................... 480 Tightening Torque Specifications............................................................................................................................................................................................. 480 Special Tools and Equipment...................................................................................................................................................................................................... 480 Special Tool................................................................................................................................................................................................................. 480 Wheels and Tires..................................................................................................................................................................................................................... 481 Precautions...................................................................................................................................................................................................................... 481 Precaution for Emergency Flat Tire Repair Kit................................................................................................................................................................................ 481 General Description.............................................................................................................................................................................................................. 481 Tires Description............................................................................................................................................................................................................ 481 Wheels Description........................................................................................................................................................................................................... 482 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 483 Wear Indicators Description.................................................................................................................................................................................................. 484 Radial Tire Waddle Description............................................................................................................................................................................................... 484 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 485 Balancing Wheels Description................................................................................................................................................................................................. 485 Repair Instructions.............................................................................................................................................................................................................. 486 General Balance Procedures................................................................................................................................................................................................... 486 Tire Rotation................................................................................................................................................................................................................ 486 Wheel Removal and Installation............................................................................................................................................................................................... 487 Tire Mounting and Dismounting................................................................................................................................................................................................ 487 Tire Repair.................................................................................................................................................................................................................. 487 Tire Repair for Emergency Repaired-Tire with Sealant......................................................................................................................................................................... 488 Specifications................................................................................................................................................................................................................... 489 Wheels and Tires Specifications.............................................................................................................................................................................................. 489 Tightening Torque Specifications............................................................................................................................................................................................. 489 Driveline / Axle......................................................................................................................................................................................................................... 491 Precautions.......................................................................................................................................................................................................................... 493 Precautions...................................................................................................................................................................................................................... 493 Precautions on Driveline / Axle.............................................................................................................................................................................................. 493 Drive Shaft / Axle................................................................................................................................................................................................................... 494 Front............................................................................................................................................................................................................................ 494 General Description.......................................................................................................................................................................................................... 494 Front Drive Shaft Construction........................................................................................................................................................................................... 494 Component Location........................................................................................................................................................................................................... 494 Front Drive Shaft Assembly Components Location........................................................................................................................................................................... 494 Diagnostic Information and Procedures........................................................................................................................................................................................ 495 Front Drive Shaft Symptom Diagnosis...................................................................................................................................................................................... 495 Repair Instructions.......................................................................................................................................................................................................... 496 Front Drive Shaft Components............................................................................................................................................................................................. 496 Front Drive Shaft Assembly On-Vehicle Inspection......................................................................................................................................................................... 497 Front Drive Shaft Assembly Removal and Installation...................................................................................................................................................................... 497 Front Drive Shaft Disassembly and Reassembly............................................................................................................................................................................. 499 Center Shaft and Center Bearing Support Disassembly and Reassembly....................................................................................................................................................... 506 Front Drive Shaft Inspection............................................................................................................................................................................................. 506 Specifications............................................................................................................................................................................................................... 507 Tightening Torque Specifications......................................................................................................................................................................................... 507 Special Tools and Equipment.................................................................................................................................................................................................. 507 Recommended Service Material............................................................................................................................................................................................. 507 Special Tool............................................................................................................................................................................................................. 507 Rear............................................................................................................................................................................................................................. 508 General Description.......................................................................................................................................................................................................... 508 Rear Drive Shaft Description............................................................................................................................................................................................. 508 Repair Instructions.......................................................................................................................................................................................................... 508 Rear Drive Shaft Components.............................................................................................................................................................................................. 508 Rear Drive Shaft Removal and Installation................................................................................................................................................................................ 509 Rear Drive Shaft Disassembly and Reassembly.............................................................................................................................................................................. 509 Specifications............................................................................................................................................................................................................... 510 Tightening Torque Specifications......................................................................................................................................................................................... 510 Special Tools and Equipment.................................................................................................................................................................................................. 510 Recommended Service Material............................................................................................................................................................................................. 510 Differential......................................................................................................................................................................................................................... 511 Precautions...................................................................................................................................................................................................................... 511 Precaution for Rear Differential Oil Leakage................................................................................................................................................................................. 511 General Description.............................................................................................................................................................................................................. 511 Rear Differential Description................................................................................................................................................................................................ 511 Diagnostic Information and Procedures............................................................................................................................................................................................ 511 Rear Differential Symptom Diagnosis.......................................................................................................................................................................................... 511 Repair Instructions.............................................................................................................................................................................................................. 512 Rear Differential Oil Level Check............................................................................................................................................................................................ 512 Rear Differential Oil Change................................................................................................................................................................................................. 512 Rear Differential Assembly Dismounting and Remounting........................................................................................................................................................................ 513 Rear Differential Components................................................................................................................................................................................................. 514 Rear Differential Disassembly and Reassembly................................................................................................................................................................................. 515 Rear Differential Inspection................................................................................................................................................................................................. 524 Specifications................................................................................................................................................................................................................... 525 Tightening Torque Specifications............................................................................................................................................................................................. 525 Special Tools and Equipment...................................................................................................................................................................................................... 525 Recommended Service Material................................................................................................................................................................................................. 525 Special Tool................................................................................................................................................................................................................. 525 Transfer............................................................................................................................................................................................................................. 527 General Description.............................................................................................................................................................................................................. 527 Transfer Description......................................................................................................................................................................................................... 527 Diagnostic Information and Procedures............................................................................................................................................................................................ 528 Transfer Symptom Diagnosis................................................................................................................................................................................................... 528 Repair Instructions.............................................................................................................................................................................................................. 528 Transfer Oil Level Check..................................................................................................................................................................................................... 528 Transfer Oil Change.......................................................................................................................................................................................................... 528 Transfer Dismounting and Remounting.......................................................................................................................................................................................... 529 Transfer Assembly Components................................................................................................................................................................................................. 531 Transfer Assembly Disassembly and Reassembly................................................................................................................................................................................. 532 Reduction Drive Gear and Reduction Driven Gear Disassembly and Reassembly.................................................................................................................................................... 535 Transfer Right Case and Left Case Disassembly and Reassembly................................................................................................................................................................. 535 Transfer Output Retainer Assembly Disassembly and Reassembly................................................................................................................................................................. 536 Transfer Assembly Inspection................................................................................................................................................................................................. 539 Bevel Gear Tooth Contact Inspection.......................................................................................................................................................................................... 540 Specifications................................................................................................................................................................................................................... 542 Tightening Torque Specifications............................................................................................................................................................................................. 542 Special Tools and Equipment...................................................................................................................................................................................................... 542 Recommended Service Material................................................................................................................................................................................................. 542 Special Tool................................................................................................................................................................................................................. 542 Propeller Shafts..................................................................................................................................................................................................................... 544 General Description.............................................................................................................................................................................................................. 544 Propeller Shaft Description.................................................................................................................................................................................................. 544 Repair Instructions.............................................................................................................................................................................................................. 544 Propeller Shaft Components................................................................................................................................................................................................... 544 Propeller Shaft Removal and Installation..................................................................................................................................................................................... 545 Propeller Shaft Inspection................................................................................................................................................................................................... 546 Propeller Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 546 Coupling Assembly Disassembly and Reassembly................................................................................................................................................................................. 546 Specifications................................................................................................................................................................................................................... 548 Tightening Torque Specifications............................................................................................................................................................................................. 548 Special Tools and Equipment...................................................................................................................................................................................................... 548 Special Tool................................................................................................................................................................................................................. 548 Brakes................................................................................................................................................................................................................................... 549 Precautions.......................................................................................................................................................................................................................... 551 Precautions...................................................................................................................................................................................................................... 551 Precautions for Brakes....................................................................................................................................................................................................... 551 Brake Control System and Diagnosis................................................................................................................................................................................................... 552 Precautions...................................................................................................................................................................................................................... 552 Precautions on Brake......................................................................................................................................................................................................... 552 General Description.............................................................................................................................................................................................................. 552 Brakes Construction.......................................................................................................................................................................................................... 552 Brake Pedal Foot Protection System Construction.............................................................................................................................................................................. 553 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 554 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 555 Diagnostic Information and Procedures............................................................................................................................................................................................ 556 Brakes Diagnosis Note........................................................................................................................................................................................................ 556 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 556 Repair Instructions.............................................................................................................................................................................................................. 559 Brake Pedal Components....................................................................................................................................................................................................... 559 Brake Pedal Free Height Inspection........................................................................................................................................................................................... 559 Brake Pedal Play Inspection.................................................................................................................................................................................................. 559 Excessive Pedal Travel Inspection............................................................................................................................................................................................ 560 Master Cylinder and Brake Fluid Level Inspection............................................................................................................................................................................. 560 Stop Light Switch Adjustment................................................................................................................................................................................................. 561 Air Bleeding of Brake System................................................................................................................................................................................................. 561 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 562 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 563 Brake Hose and Pipe Inspection............................................................................................................................................................................................... 563 Master Cylinder Components................................................................................................................................................................................................... 564 Master Cylinder Reservoir Removal and Installation (NISSIN).................................................................................................................................................................. 565 Master Cylinder Reservoir Removal and Installation (BOSCH)................................................................................................................................................................... 566 Master Cylinder Assembly Removal and Installation (NISSIN)................................................................................................................................................................... 566 Master Cylinder Assembly Removal and Installation (BOSCH).................................................................................................................................................................... 568 Master Cylinder Assembly Disassembly and Assembly (NISSIN)................................................................................................................................................................... 569 Brake Booster Components..................................................................................................................................................................................................... 571 Booster Operation Inspection................................................................................................................................................................................................. 572 Brake Booster Removal and Installation....................................................................................................................................................................................... 573 Brake Booster Inspection and Adjustment (NISSIN Brake Master Cylinder Model)................................................................................................................................................. 574 Brake Booster Inspection (BOSCH Brake Master Cylinder Model)................................................................................................................................................................. 574 Specifications................................................................................................................................................................................................................... 575 Tightening Torque Specifications............................................................................................................................................................................................. 575 Special Tools and Equipment...................................................................................................................................................................................................... 575 Recommended Service Material................................................................................................................................................................................................. 575 Front Brakes......................................................................................................................................................................................................................... 576 General Description.............................................................................................................................................................................................................. 576 Brake Caliper Type Identification............................................................................................................................................................................................ 576 Repair Instructions.............................................................................................................................................................................................................. 577 Front Disc Brake Components.................................................................................................................................................................................................. 577 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................... 578 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 578 Front Disc Brake Pad Inspection.............................................................................................................................................................................................. 579 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 580 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 581 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 583 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 583 Front Brake Disc Inspection.................................................................................................................................................................................................. 584 Specifications................................................................................................................................................................................................................... 585 Tightening Torque Specifications............................................................................................................................................................................................. 585 Special Tools and Equipment...................................................................................................................................................................................................... 585 Recommended Service Material................................................................................................................................................................................................. 585 Special Tool................................................................................................................................................................................................................. 585 Rear Brakes.......................................................................................................................................................................................................................... 586 Repair Instructions.............................................................................................................................................................................................................. 586 Rear Drum Brake Components................................................................................................................................................................................................... 586 Rear Brake Drum Removal and Installation..................................................................................................................................................................................... 587 Rear Brake Drum and Shoe Inspection.......................................................................................................................................................................................... 588 Rear Brake Shoe Removal and Installation..................................................................................................................................................................................... 589 Rear Brake Shoe Inspection................................................................................................................................................................................................... 590 Wheel Cylinder Removal and Installation...................................................................................................................................................................................... 590 Wheel Cylinder Inspection.................................................................................................................................................................................................... 591 Brake Back Plate Removal and Installation (2WD Vehicle)...................................................................................................................................................................... 591 Brake Back Plate Removal and Installation (4WD Vehicle)...................................................................................................................................................................... 592 Specifications................................................................................................................................................................................................................... 592 Tightening Torque Specifications............................................................................................................................................................................................. 592 Special Tools and Equipment...................................................................................................................................................................................................... 592 Recommended Service Material................................................................................................................................................................................................. 592 Special Tool................................................................................................................................................................................................................. 592 Parking Brake........................................................................................................................................................................................................................ 593 General Description.............................................................................................................................................................................................................. 593 Parking Brake Cable Construction............................................................................................................................................................................................. 593 Repair Instructions.............................................................................................................................................................................................................. 594 Parking Brake Inspection and Adjustment...................................................................................................................................................................................... 594 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 595 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 595 Specifications................................................................................................................................................................................................................... 596 Tightening Torque Specifications............................................................................................................................................................................................. 596 Special Tools and Equipment...................................................................................................................................................................................................... 596 Recommended Service Material................................................................................................................................................................................................. 596 ABS.................................................................................................................................................................................................................................. 597 Precautions...................................................................................................................................................................................................................... 597 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 597 Precautions in On-Vehicle Service............................................................................................................................................................................................ 597 General Description.............................................................................................................................................................................................................. 598 ABS Description.............................................................................................................................................................................................................. 598 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 598 Schematic and Routing Diagram.................................................................................................................................................................................................... 599 ABS Schematic................................................................................................................................................................................................................ 599 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 600 Component Location............................................................................................................................................................................................................... 601 ABS Components Location...................................................................................................................................................................................................... 601 Front Wheel Speed Sensor Components Location................................................................................................................................................................................. 602 Rear Wheel Speed Sensor Components Location.................................................................................................................................................................................. 602 Diagnostic Information and Procedures............................................................................................................................................................................................ 603 ABS Check.................................................................................................................................................................................................................... 603 ABS Warning Lamp Check....................................................................................................................................................................................................... 605 EBD Warning Lamp (Brake Warning Lamp) Check.................................................................................................................................................................................. 605 DTC Check.................................................................................................................................................................................................................... 606 DTC Table.................................................................................................................................................................................................................... 606 DTC Clearance................................................................................................................................................................................................................ 607 Scan Tool Data............................................................................................................................................................................................................... 607 ABS Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................... 608 ABS Warning Lamp Comes ON Steady............................................................................................................................................................................................. 609 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON............................................................................................................................................................ 611 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady........................................................................................................................................................................ 612 Serial Data Link Circuit Check............................................................................................................................................................................................... 613 DTC C1015: G Sensor Circuit.................................................................................................................................................................................................. 615 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring.................................................................. 615 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.... 617 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 618 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 619 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 620 DTC C1071: ABS Control Module................................................................................................................................................................................................ 621 Repair Instructions.............................................................................................................................................................................................................. 622 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 622 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 623 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 623 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 623 Front Wheel Speed Sensor On-Vehicle Inspection............................................................................................................................................................................... 625 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 625 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 626 Rear Wheel Speed Sensor On-Vehicle Inspection................................................................................................................................................................................ 626 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 627 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 628 Front Wheel Speed Sensor Ring On-Vehicle Inspection.......................................................................................................................................................................... 628 Front Wheel Speed Sensor Ring Removal and Installation....................................................................................................................................................................... 628 Rear Wheel Speed Sensor Ring On-Vehicle Inspection........................................................................................................................................................................... 629 Rear Wheel Speed Sensor Ring Removal and Installation (2WD Vehicle).......................................................................................................................................................... 629 Rear Wheel Speed Sensor Ring Removal and Installation (4WD Vehicle).......................................................................................................................................................... 629 ABS Sensor Ring Inspection................................................................................................................................................................................................... 629 Specifications................................................................................................................................................................................................................... 630 Tightening Torque Specifications............................................................................................................................................................................................. 630 Special Tools and Equipment...................................................................................................................................................................................................... 630 Special Tool................................................................................................................................................................................................................. 630 Transmission / Transaxle................................................................................................................................................................................................................. 631 Precautions.......................................................................................................................................................................................................................... 635 Precautions...................................................................................................................................................................................................................... 635 Precautions on Transmission / Transaxle...................................................................................................................................................................................... 635 Automatic Transmission/Transaxle..................................................................................................................................................................................................... 636 Precautions...................................................................................................................................................................................................................... 636 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 636 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 636 General Description.............................................................................................................................................................................................................. 638 A/T Description.............................................................................................................................................................................................................. 638 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................................................................................................. 641 Table of Component Operation................................................................................................................................................................................................. 642 A/T Diagnosis General Description............................................................................................................................................................................................ 643 On-Board Diagnostic System Description....................................................................................................................................................................................... 643 CAN Communication System Description......................................................................................................................................................................................... 644 Schematic and Routing Diagram.................................................................................................................................................................................................... 645 Transmission Control Module (TCM) Wiring Diagram............................................................................................................................................................................. 645 Automatic Gear Shift Table................................................................................................................................................................................................... 647 Component Location............................................................................................................................................................................................................... 649 Electronic Shift Control System Components Location.......................................................................................................................................................................... 649 Diagnostic Information and Procedures............................................................................................................................................................................................ 651 A/T System Check............................................................................................................................................................................................................. 651 Visual Inspection............................................................................................................................................................................................................ 653 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 654 Transmission Warning Light Check............................................................................................................................................................................................. 654 DTC Table.................................................................................................................................................................................................................... 654 DTC Check.................................................................................................................................................................................................................... 656 DTC Clearance................................................................................................................................................................................................................ 657 Fail-Safe Table.............................................................................................................................................................................................................. 657 Scan Tool Data............................................................................................................................................................................................................... 660 A/T Basic Check.............................................................................................................................................................................................................. 663 Road Test.................................................................................................................................................................................................................... 663 Manual Road Test............................................................................................................................................................................................................. 665 Engine Brake Test............................................................................................................................................................................................................ 666 Stall Test................................................................................................................................................................................................................... 666 Time Lag Test................................................................................................................................................................................................................ 667 Line Pressure Test........................................................................................................................................................................................................... 668 “P” Range Test............................................................................................................................................................................................................... 668 A/T Symptom Diagnosis........................................................................................................................................................................................................ 669 No Gear Shift to 4th gear.................................................................................................................................................................................................... 676 No Lock-Up Occurs............................................................................................................................................................................................................ 677 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON.................................................................................................................................... 678 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON.......................................................................................................................................... 678 DTC P0602: Control Module Programming Error.................................................................................................................................................................................. 678 DTC P0705: Transmission Range Sensor Circuit Malfunction..................................................................................................................................................................... 679 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................................................................................................. 681 DTC P0711: Transmission Fluid Temperature Sensor “A” Control Range / Performance............................................................................................................................................. 683 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low................................................................................................................................................................. 684 DTC P0713: Transmission Fluid Temperature Sensor Circuit High................................................................................................................................................................ 685 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction.................................................................................................................................................................. 686 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal....................................................................................................................................................................... 688 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON............................................................................................................................................... 689 DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction................................................................................................................................................................ 690 DTC P0787: Shift / Timing Solenoid Control Circuit Low....................................................................................................................................................................... 692 DTC P0788: Shift / Timing Solenoid Control Circuit High...................................................................................................................................................................... 694 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance................................................................................................................................................. 696 DTC P0962: Pressure Control Solenoid Control Circuit Low..................................................................................................................................................................... 698 DTC P0963: Pressure Control Solenoid Control Circuit High.................................................................................................................................................................... 700 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low................................................................................................................. 702 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High.................................................................................................................................... 704 DTC P1702: Internal Control Module Memory Check Sum Error.................................................................................................................................................................... 706 DTC P1703: Can Invalid Data - TCM............................................................................................................................................................................................ 706 DTC P1723: Range Select Switch Malfunction................................................................................................................................................................................... 707 DTC P1774: Control Module Communication Bus Off.............................................................................................................................................................................. 708 DTC P1775: High Speed CAN Communication Bus Off (Transmission Error)......................................................................................................................................................... 713 DTC P1777: TCM Lost Communication with ECM (Reception Error)................................................................................................................................................................. 716 DTC P1778: TCM Lost Communication with BCM (Reception Error)................................................................................................................................................................. 719 DTC P1878: Torque Converter Clutch Shudder................................................................................................................................................................................... 722 DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance....................................................................................................................... 722 DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High...................................................................................................................................... 724 DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low............................................................................................................................... 727 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 729 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 733 Brake Interlock System Inspection............................................................................................................................................................................................ 734 Repair Instructions.............................................................................................................................................................................................................. 735 Learning Control Initialization.............................................................................................................................................................................................. 735 A/T Fluid Level Check........................................................................................................................................................................................................ 735 A/T Fluid Change............................................................................................................................................................................................................. 736 Selector Lever Components.................................................................................................................................................................................................... 736 Select Lever Assembly Installation........................................................................................................................................................................................... 737 Select Lever Knob Installation............................................................................................................................................................................................... 737 Selector Lever Inspection.................................................................................................................................................................................................... 737 Select Cable Components...................................................................................................................................................................................................... 737 Select Cable Removal and Installation........................................................................................................................................................................................ 738 Select Cable Adjustment...................................................................................................................................................................................................... 738 Transmission Range Sensor (Shift Switch) Inspection and Adjustment........................................................................................................................................................... 739 Output Shaft Speed Sensor (VSS) Removal and Installation..................................................................................................................................................................... 739 Output Shaft Speed Sensor (VSS) Inspection................................................................................................................................................................................... 740 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 740 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 740 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 741 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 741 “3” Position Switch Inspection............................................................................................................................................................................................... 742 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation................................................................................................................................... 742 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection................................................................................................................................................ 743 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...................................................................................................... 745 Pressure Control Solenoid Valve Inspection................................................................................................................................................................................... 745 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 746 A/T Relay Inspection......................................................................................................................................................................................................... 747 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 747 Shift Lock Solenoid Inspection............................................................................................................................................................................................... 748 Shift Lock Solenoid Replacement.............................................................................................................................................................................................. 748 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 749 A/T Fluid Cooler Hoses Replacement........................................................................................................................................................................................... 750 Automatic Transaxle Unit Components.......................................................................................................................................................................................... 750 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................... 751 Automatic Transaxle Assembly Components...................................................................................................................................................................................... 753 Automatic Transaxle Unit Disassembly......................................................................................................................................................................................... 754 Oil Pump Assembly Components................................................................................................................................................................................................. 766 Oil Pump Assembly Disassembly and Reassembly................................................................................................................................................................................. 767 Oil Pump Assembly Inspection................................................................................................................................................................................................. 767 Direct Clutch Assembly Components............................................................................................................................................................................................ 769 Direct Clutch Assembly Preliminary Check..................................................................................................................................................................................... 769 Direct Clutch Assembly Disassembly and Reassembly............................................................................................................................................................................ 770 Direct Clutch Assembly Inspection............................................................................................................................................................................................ 772 Forward and Reverse Clutch Assembly Components............................................................................................................................................................................... 773 Forward and Reverse Clutch Assembly Preliminary Check........................................................................................................................................................................ 774 Forward and Reverse Clutch Assembly Disassembly and Reassembly............................................................................................................................................................... 774 Forward and Reverse Clutch Assembly Inspection............................................................................................................................................................................... 778 2nd Brake Piston Assembly Components......................................................................................................................................................................................... 779 2nd Brake Piston Assembly Disassembly and Reassembly......................................................................................................................................................................... 779 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components.................................................................................................................................................... 780 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly.................................................................................................................................... 781 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection.................................................................................................................................................... 782 Countershaft Assembly Components............................................................................................................................................................................................. 783 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 783 Valve Body Assembly Components............................................................................................................................................................................................... 784 Valve Body Assembly Disassembly and Reassembly............................................................................................................................................................................... 785 Differential Assembly Components............................................................................................................................................................................................. 786 Differential Assembly Disassembly and Reassembly............................................................................................................................................................................. 787 Differential Assembly Inspection............................................................................................................................................................................................. 788 Torque Converter Housing Disassembly and Reassembly.......................................................................................................................................................................... 789 Transaxle Case Disassembly and Reassembly.................................................................................................................................................................................... 791 Automatic Transaxle Unit Inspection and Adjustment........................................................................................................................................................................... 792 Automatic Transaxle Unit Assembly............................................................................................................................................................................................ 795 Specifications................................................................................................................................................................................................................... 814 Tightening Torque Specifications............................................................................................................................................................................................. 814 Special Tools and Equipment...................................................................................................................................................................................................... 815 Recommended Service Material................................................................................................................................................................................................. 815 Special Tool................................................................................................................................................................................................................. 815 Manual Transmission/Transaxle........................................................................................................................................................................................................ 818 For M13 Engine Model............................................................................................................................................................................................................. 818 General Description.......................................................................................................................................................................................................... 818 Manual Transaxle Construction and Servicing.............................................................................................................................................................................. 818 Diagnostic Information and Procedures........................................................................................................................................................................................ 821 Manual Transaxle Symptom Diagnosis....................................................................................................................................................................................... 821 Repair Instructions.......................................................................................................................................................................................................... 821 Manual Transaxle Oil Change.............................................................................................................................................................................................. 821 Differential Side Oil Seal Replacement................................................................................................................................................................................... 822 Gear Shift Control Lever and Cable Components............................................................................................................................................................................ 823 Gear Shift Control Lever and Cable Removal and Installation.............................................................................................................................................................. 824 Gear Select Control Cable Adjustment..................................................................................................................................................................................... 824 Vehicle Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................... 825 Back Up Lamp Switch Removal and Installation............................................................................................................................................................................. 825 Back Up Lamp Switch Inspection........................................................................................................................................................................................... 826 Manual Transaxle Unit Components......................................................................................................................................................................................... 826 Manual Transaxle Unit Dismounting and Remounting......................................................................................................................................................................... 827 Gear Shift and Select Shaft Assembly Components.......................................................................................................................................................................... 829 Gear Shift and Select Shaft Assembly Removal and Installation............................................................................................................................................................ 830 Gear Shift and Select Shaft Disassembly and Assembly..................................................................................................................................................................... 831 Manual Transaxle Assembly Components..................................................................................................................................................................................... 832 Fifth Gear Disassembly and Assembly...................................................................................................................................................................................... 833 Manual Transaxle Assembly Disassembly and Reassembly..................................................................................................................................................................... 836 Transaxle Right Case Disassembly and Assembly............................................................................................................................................................................ 840 Transaxle Left Case Disassembly and Assembly............................................................................................................................................................................. 841 Input Shaft and Countershaft Components.................................................................................................................................................................................. 842 Input Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 843 Countershaft Assembly Disassembly and Reassembly......................................................................................................................................................................... 845 Synchronizer Parts Inspection............................................................................................................................................................................................ 848 Gear Shift Shaft Components.............................................................................................................................................................................................. 849 5th and Reverse Gear Shift Shafts Disassembly and Assembly............................................................................................................................................................... 849 Gear Shift Shaft and Fork Inspection..................................................................................................................................................................................... 850 Differential Components.................................................................................................................................................................................................. 850 Differential Disassembly and Assembly.................................................................................................................................................................................... 851 Specifications............................................................................................................................................................................................................... 853 Tightening Torque Specifications......................................................................................................................................................................................... 853 Special Tools and Equipment.................................................................................................................................................................................................. 854 Recommended Service Material............................................................................................................................................................................................. 854 Special Tool............................................................................................................................................................................................................. 854 For M15 Engine Model............................................................................................................................................................................................................. 856 General Description.......................................................................................................................................................................................................... 856 Manual Transaxle Construction and Servicing.............................................................................................................................................................................. 856 Diagnostic Information and Procedures........................................................................................................................................................................................ 858 Manual Transaxle Symptom Diagnosis....................................................................................................................................................................................... 858 Repair Instructions.......................................................................................................................................................................................................... 858 Manual Transaxle Oil Change.............................................................................................................................................................................................. 858 Differential Side Oil Seal Replacement................................................................................................................................................................................... 859 Gear Shift Control Lever and Cable Components............................................................................................................................................................................ 860 Gear Shift Control Lever and Cable Removal and Installation.............................................................................................................................................................. 860 Gear Select Control Cable Adjustment..................................................................................................................................................................................... 860 Vehicle Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................... 860 Back Up Lamp Switch Removal and Installation............................................................................................................................................................................. 860 Back Up Lamp Switch Inspection........................................................................................................................................................................................... 861 Manual Transaxle Unit Components......................................................................................................................................................................................... 861 Manual Transaxle Unit Dismounting and Remounting......................................................................................................................................................................... 862 Gear Shift and Select Shaft Assembly Components.......................................................................................................................................................................... 863 Gear Shift and Select Shaft Assembly Removal and Installation............................................................................................................................................................ 863 Gear Shift and Select Shaft Disassembly and Assembly..................................................................................................................................................................... 864 Manual Transaxle Assembly Components..................................................................................................................................................................................... 865 Fifth Gear Disassembly and Assembly...................................................................................................................................................................................... 866 Manual Transaxle Assembly Disassembly and Reassembly..................................................................................................................................................................... 869 Transaxle Right Case Disassembly and Assembly............................................................................................................................................................................ 875 Transaxle Left Case Disassembly and Assembly............................................................................................................................................................................. 876 Input Shaft and Countershaft Components.................................................................................................................................................................................. 877 Input Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 878 Countershaft Assembly Disassembly and Reassembly......................................................................................................................................................................... 880 Synchronizer Parts Inspection............................................................................................................................................................................................ 883 Gear Shift Shaft Components.............................................................................................................................................................................................. 883 5th and Reverse Gear Shift Shafts Disassembly and Assembly............................................................................................................................................................... 884 Gear Shift Shaft and Fork Inspection..................................................................................................................................................................................... 884 Differential Components.................................................................................................................................................................................................. 885 Differential Disassembly and Assembly.................................................................................................................................................................................... 885 Specifications............................................................................................................................................................................................................... 888 Tightening Torque Specifications......................................................................................................................................................................................... 888 Special Tools and Equipment.................................................................................................................................................................................................. 888 Recommended Service Material............................................................................................................................................................................................. 888 Special Tool............................................................................................................................................................................................................. 889 Clutch............................................................................................................................................................................................................................... 891 General Description.............................................................................................................................................................................................................. 891 Clutch Construction.......................................................................................................................................................................................................... 891 Diagnostic Information and Procedures............................................................................................................................................................................................ 892 Clutch System Symptom Diagnosis.............................................................................................................................................................................................. 892 Repair Instructions.............................................................................................................................................................................................................. 893 Clutch Pedal Inspection...................................................................................................................................................................................................... 893 Clutch Fluid Level Inspection................................................................................................................................................................................................ 893 Air Bleeding of Clutch System................................................................................................................................................................................................ 894 Clutch Pedal Position (CPP) Switch Removal and Installation (Hong Kong Model)................................................................................................................................................ 895 Clutch Pedal Position (CPP) Switch Inspection and Adjustment (Hong Kong Model)............................................................................................................................................... 895 Clutch Fluid Pipe and Hose Components........................................................................................................................................................................................ 896 Clutch Fluid Pipe Removal and Installation................................................................................................................................................................................... 897 Clutch Fluid Pipe Inspection................................................................................................................................................................................................. 897 Clutch Master Cylinder Removal and Installation.............................................................................................................................................................................. 898 Clutch Operating Cylinder Removal and Installation........................................................................................................................................................................... 898 Clutch Pedal and Clutch Pedal Bracket Components............................................................................................................................................................................. 899 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................................................................................................ 900 Clutch Cover, Clutch Disc and Flywheel Removal and Installation.............................................................................................................................................................. 900 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................................................................................................ 902 Clutch Release System Removal and Installation............................................................................................................................................................................... 902 Clutch Release System Inspection............................................................................................................................................................................................. 904 Specifications................................................................................................................................................................................................................... 905 Tightening Torque Specifications............................................................................................................................................................................................. 905 Special Tools and Equipment...................................................................................................................................................................................................... 905 Recommended Service Material................................................................................................................................................................................................. 905 Special Tool................................................................................................................................................................................................................. 906 Steering................................................................................................................................................................................................................................. 907 Precautions.......................................................................................................................................................................................................................... 909 Precautions...................................................................................................................................................................................................................... 909 Precautions on Steering...................................................................................................................................................................................................... 909 Steering General Diagnosis........................................................................................................................................................................................................... 910 Precautions...................................................................................................................................................................................................................... 910 Precautions for Steering Diagnosis........................................................................................................................................................................................... 910 Diagnostic Information and Procedures............................................................................................................................................................................................ 911 Steering Symptom Diagnosis................................................................................................................................................................................................... 911 Steering Wheel and Column............................................................................................................................................................................................................ 912 Precautions...................................................................................................................................................................................................................... 912 Service Precautions of Steering Wheel and Column............................................................................................................................................................................. 912 Diagnostic Information and Procedures............................................................................................................................................................................................ 912 Checking Steering Column for Accident Damage................................................................................................................................................................................. 912 Repair Instructions.............................................................................................................................................................................................................. 913 Steering Wheel and Column Construction....................................................................................................................................................................................... 913 Steering Wheel Removal and Installation...................................................................................................................................................................................... 914 Contact Coil Cable Assembly Removal and Installation......................................................................................................................................................................... 915 Centering Contact Coil Cable Assembly........................................................................................................................................................................................ 916 Contact Coil Cable Assembly Inspection....................................................................................................................................................................................... 916 Steering Column Removal and Installation..................................................................................................................................................................................... 916 Steering Column Inspection................................................................................................................................................................................................... 918 Ignition Switch Cylinder Assembly Removal and Installation (without Keyless Start System).................................................................................................................................... 918 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................ 919 Steering Lower Shaft Removal and Installation................................................................................................................................................................................ 919 Specifications................................................................................................................................................................................................................... 920 Tightening Torque Specifications............................................................................................................................................................................................. 920 Special Tools and Equipment...................................................................................................................................................................................................... 920 Special Tool................................................................................................................................................................................................................. 920 Power Assisted Steering System....................................................................................................................................................................................................... 921 Precautions...................................................................................................................................................................................................................... 921 Steering System Note......................................................................................................................................................................................................... 921 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 921 General Description.............................................................................................................................................................................................................. 922 P/S System Description....................................................................................................................................................................................................... 922 EPS Diagnosis General Description............................................................................................................................................................................................ 923 On-Board Diagnostic System Description....................................................................................................................................................................................... 923 Schematic and Routing Diagram.................................................................................................................................................................................................... 924 EPS System Wiring Circuit Diagram............................................................................................................................................................................................ 924 Diagnostic Information and Procedures............................................................................................................................................................................................ 925 EPS System Check............................................................................................................................................................................................................. 925 “EPS” Warning Lamp Check..................................................................................................................................................................................................... 926 DTC Check.................................................................................................................................................................................................................... 927 DTC Clearance................................................................................................................................................................................................................ 927 DTC Table.................................................................................................................................................................................................................... 927 Scan Tool Data............................................................................................................................................................................................................... 929 P/S System Symptom Diagnosis................................................................................................................................................................................................. 930 Serial Data Link Circuit Check............................................................................................................................................................................................... 931 “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stops................................................................................................................................................... 932 “EPS” Warning Lamp Comes ON Steady even after Engine Starts.................................................................................................................................................................. 934 DTC C1113 / C1117 / C1118: Torque Sensor Circuit Failure..................................................................................................................................................................... 935 DTC C1114: Torque Sensor 5 V Power Supply Circuit Failure.................................................................................................................................................................... 936 DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure................................................................................................................................................................... 937 DTC C1121 / C1123 / C1124: VSS Circuit Failure............................................................................................................................................................................... 938 DTC C1122: Engine Speed Signal Circuit Failure............................................................................................................................................................................... 940 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure..................................................................................................................................................................... 941 DTC C1153: P/S Control Module Power Supply Circuit Voltage Low............................................................................................................................................................... 942 DTC C1155: P/S Control Module Failure........................................................................................................................................................................................ 944 Inspection of P/S Control Module and Its Circuits............................................................................................................................................................................ 944 Steering Wheel Play Check.................................................................................................................................................................................................... 947 Steering Force Check......................................................................................................................................................................................................... 947 Repair Instructions.............................................................................................................................................................................................................. 948 Steering Gear Case Assembly Components....................................................................................................................................................................................... 948 Tie-Rod End Boot On-Vehicle Inspection....................................................................................................................................................................................... 950 Tie-Rod End Removal and Installation......................................................................................................................................................................................... 950 Tie-Rod End Inspection....................................................................................................................................................................................................... 951 Steering Shaft Joint On-Vehicle Inspection................................................................................................................................................................................... 951 Steering Gear Case Assembly Removal and Installation......................................................................................................................................................................... 951 Steering Rack Boot Inspection................................................................................................................................................................................................ 954 Tie-Rod / Rack Boot Removal and Installation................................................................................................................................................................................. 955 Steering Rack Plunger Removal and Installation............................................................................................................................................................................... 956 Steering Rack Plunger Inspection............................................................................................................................................................................................. 957 P/S Control Module Removal and Installation.................................................................................................................................................................................. 957 Torque Sensor and Its Circuit Inspection..................................................................................................................................................................................... 957 Motor Assembly Inspection.................................................................................................................................................................................................... 958 Specifications................................................................................................................................................................................................................... 959 Tightening Torque Specifications............................................................................................................................................................................................. 959 Special Tools and Equipment...................................................................................................................................................................................................... 960 Recommended Service Material................................................................................................................................................................................................. 960 Special Tool................................................................................................................................................................................................................. 960 HVAC..................................................................................................................................................................................................................................... 961 Precautions.......................................................................................................................................................................................................................... 964 Precautions...................................................................................................................................................................................................................... 964 Precautions on HVAC.......................................................................................................................................................................................................... 964 Heater and Ventilation............................................................................................................................................................................................................... 965 General Description.............................................................................................................................................................................................................. 965 Heater and Ventilation Construction.......................................................................................................................................................................................... 965 Schematic and Routing Diagram.................................................................................................................................................................................................... 966 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................ 966 Diagnostic Information and Procedures............................................................................................................................................................................................ 967 Heater and Ventilation Symptom Diagnosis..................................................................................................................................................................................... 967 Repair Instructions.............................................................................................................................................................................................................. 968 HVAC Unit Components......................................................................................................................................................................................................... 968 HVAC Unit Removal and Installation........................................................................................................................................................................................... 968 Blower Motor Removal and Installation........................................................................................................................................................................................ 968 Blower Motor Inspection...................................................................................................................................................................................................... 968 Blower Motor Resistor Removal and Installation............................................................................................................................................................................... 969 Blower Motor Resistor Inspection............................................................................................................................................................................................. 969 Blower Motor Relay Inspection................................................................................................................................................................................................ 970 HVAC Control Unit Components................................................................................................................................................................................................. 970 HVAC Control Unit Removal and Installation................................................................................................................................................................................... 971 Blower Speed Selector Inspection............................................................................................................................................................................................. 973 Air Intake Selector Inspection............................................................................................................................................................................................... 973 Air Intake Control Actuator Removal and Installation......................................................................................................................................................................... 973 Air Intake Control Actuator Inspection....................................................................................................................................................................................... 974 Center Ventilation Louver Removal and Installation........................................................................................................................................................................... 974 Side Ventilation Louver Removal and Installation............................................................................................................................................................................. 975 HVAC Air Filter Removal and Installation (If Equipped)....................................................................................................................................................................... 976 HVAC Air Filter Inspection (If Equipped)..................................................................................................................................................................................... 976 Air Conditioning System.............................................................................................................................................................................................................. 977 Manual Type...................................................................................................................................................................................................................... 977 Precautions.................................................................................................................................................................................................................. 977 A/C System Caution....................................................................................................................................................................................................... 977 Precautions on Servicing A/C System...................................................................................................................................................................................... 977 General Description.......................................................................................................................................................................................................... 979 Refrigerant Type Identification.......................................................................................................................................................................................... 979 Sub-Cool A/C System Description.......................................................................................................................................................................................... 980 A/C Operation Description................................................................................................................................................................................................ 981 Schematic and Routing Diagram................................................................................................................................................................................................ 981 Major Components of A/C System........................................................................................................................................................................................... 981 A/C System Wiring Diagram................................................................................................................................................................................................ 983 Diagnostic Information and Procedures........................................................................................................................................................................................ 984 A/C System Symptom Diagnosis............................................................................................................................................................................................. 984 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 986 A/C System Performance Inspection........................................................................................................................................................................................ 987 A/C System Inspection at ECM............................................................................................................................................................................................. 992 Repair Instructions.......................................................................................................................................................................................................... 992 Operation Procedure for Refrigerant Charge............................................................................................................................................................................... 992 Condenser Assembly On-Vehicle Inspection................................................................................................................................................................................. 997 Condenser Assembly Removal and Installation.............................................................................................................................................................................. 998 Receiver/Dryer Removal and Installation.................................................................................................................................................................................. 998 HVAC Unit Components..................................................................................................................................................................................................... 999 HVAC Unit Removal and Installation.......................................................................................................................................................................................1000 Evaporator Inspection....................................................................................................................................................................................................1000 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation...........................................................................................................................................1001 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection.........................................................................................................................................................1001 Expansion Valve Removal and Installation.................................................................................................................................................................................1002 Expansion Valve Inspection...............................................................................................................................................................................................1002 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...............................................................................................................................................................1002 A/C Refrigerant Pressure Sensor Removal and Installation.................................................................................................................................................................1002 A/C Switch Inspection....................................................................................................................................................................................................1003 Compressor Relay Inspection..............................................................................................................................................................................................1003 Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1003 Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1004 Compressor Assembly Removal and Installation.............................................................................................................................................................................1004 Compressor Assembly Components...........................................................................................................................................................................................1005 Magnet Clutch Inspection.................................................................................................................................................................................................1005 Magnet Clutch Removal and Installation...................................................................................................................................................................................1005 Relief Valve Inspection..................................................................................................................................................................................................1007 Relief Valve Removal and Installation....................................................................................................................................................................................1008 Specifications...............................................................................................................................................................................................................1008 Tightening Torque Specifications.........................................................................................................................................................................................1008 Special Tools and Equipment..................................................................................................................................................................................................1009 Recommended Service Material.............................................................................................................................................................................................1009 Special Tool.............................................................................................................................................................................................................1009 Automatic Type...................................................................................................................................................................................................................1010 Precautions..................................................................................................................................................................................................................1010 A/C System Caution.......................................................................................................................................................................................................1010 Precautions in Diagnosing Trouble........................................................................................................................................................................................1010 Precautions on Servicing A/C System......................................................................................................................................................................................1010 General Description..........................................................................................................................................................................................................1010 Auto A/C System Description..............................................................................................................................................................................................1010 HVAC Control Module Operation Description................................................................................................................................................................................1012 Refrigerant Type Identification..........................................................................................................................................................................................1012 Sub-Cool A/C System Description..........................................................................................................................................................................................1012 A/C Operation Description................................................................................................................................................................................................1012 On-Board Diagnostic System Description...................................................................................................................................................................................1013 Schematic and Routing Diagram................................................................................................................................................................................................1013 Major Components of A/C System...........................................................................................................................................................................................1013 A/C System Wiring Diagram................................................................................................................................................................................................1014 Diagnostic Information and Procedures........................................................................................................................................................................................1015 A/C System Symptom Diagnosis.............................................................................................................................................................................................1015 Abnormal Noise Symptom Diagnosis of A/C System...........................................................................................................................................................................1018 DTC Check................................................................................................................................................................................................................1018 DTC Clearance............................................................................................................................................................................................................1019 DTC Table................................................................................................................................................................................................................1020 Fail-Safe Table..........................................................................................................................................................................................................1021 Scan Tool Data...........................................................................................................................................................................................................1022 Air Conditioning System Check............................................................................................................................................................................................1023 Visual Inspection........................................................................................................................................................................................................1025 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction..................................................................................................................................................1025 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction..........................................................................................................................................1026 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction.................................................................................................................................................................1028 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................................................................................................1029 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction....................................................................................................................................1031 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction...................................................................................................................................................1033 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction......................................................................................................................................................1036 DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction..........................................................................................................................................................1038 DTC B1546: A/C Refrigerant Pressure Malfunction..........................................................................................................................................................................1039 DTC B1551: Serial Communication Circuit Malfunction......................................................................................................................................................................1040 DTC B1552: Serial Communication Signal Malfunction.......................................................................................................................................................................1041 DTC B1553: CAN Communication Signal Malfunction..........................................................................................................................................................................1041 DTC B1557: Vehicle Speed Sensor Signal Malfunction.......................................................................................................................................................................1042 DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction..........................................................................................................................................................1042 DTC B1562: Outside Air Temperature Sensor Signal Malfunction.............................................................................................................................................................1042 DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction............................................................................................................................................................1043 Inspection of HVAC Control Module and Its Circuit........................................................................................................................................................................1043 A/C System Performance Inspection........................................................................................................................................................................................1046 A/C System Inspection at ECM.............................................................................................................................................................................................1046 Repair Instructions..........................................................................................................................................................................................................1047 Operation Procedure for Refrigerant Charge...............................................................................................................................................................................1047 HVAC Unit Components.....................................................................................................................................................................................................1048 HVAC Unit Removal and Installation.......................................................................................................................................................................................1049 Temperature Control Actuator Removal and Installation....................................................................................................................................................................1049 Temperature Control Actuator Inspection..................................................................................................................................................................................1049 Air Flow Control Actuator Removal and Installation.......................................................................................................................................................................1050 Air Flow Control Actuator Inspection.....................................................................................................................................................................................1050 Air Intake Control Actuator Removal and Installation.....................................................................................................................................................................1051 Air Intake Control Actuator Inspection...................................................................................................................................................................................1051 Actuator Linkage Inspection..............................................................................................................................................................................................1052 Blower Motor Controller Removal and Installation.........................................................................................................................................................................1052 Blower Motor Controller Inspection.......................................................................................................................................................................................1052 HVAC Control Module Removal and Installation.............................................................................................................................................................................1052 Sunload Sensor Removal and Installation..................................................................................................................................................................................1053 Sunload Sensor Inspection................................................................................................................................................................................................1053 Outside Air Temperature Sensor Removal and Installation..................................................................................................................................................................1053 Outside Air Temperature Sensor Inspection................................................................................................................................................................................1053 Inside Air Temperature Sensor Removal and Installation...................................................................................................................................................................1053 Inside Air Temperature Sensor Inspection.................................................................................................................................................................................1054 Condenser Assembly On-Vehicle Inspection.................................................................................................................................................................................1054 Condenser Assembly Removal and Installation..............................................................................................................................................................................1054 Receiver/Dryer Removal and Installation..................................................................................................................................................................................1054 Evaporator Inspection....................................................................................................................................................................................................1054 Evaporator Temperature Sensor Removal and Installation...................................................................................................................................................................1054 Evaporator Temperature Sensor Inspection.................................................................................................................................................................................1054 Expansion Valve Removal and Installation.................................................................................................................................................................................1054 Expansion Valve Inspection...............................................................................................................................................................................................1054 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...............................................................................................................................................................1054 A/C Refrigerant Pressure Sensor Removal and Installation.................................................................................................................................................................1054 Compressor Relay Inspection..............................................................................................................................................................................................1054 Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1054 Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1054 Compressor Assembly Removal and Installation.............................................................................................................................................................................1054 Compressor Assembly Components...........................................................................................................................................................................................1054 Magnet Clutch Removal and Installation...................................................................................................................................................................................1054 Magnet Clutch Inspection.................................................................................................................................................................................................1054 Relief Valve Inspection..................................................................................................................................................................................................1054 Special Tools and Equipment..................................................................................................................................................................................................1055 Special Tool.............................................................................................................................................................................................................1055 Restraint................................................................................................................................................................................................................................1057 Precautions..........................................................................................................................................................................................................................1059 Precautions......................................................................................................................................................................................................................1059 Precautions on Restraint.....................................................................................................................................................................................................1059 Seat Belts...........................................................................................................................................................................................................................1060 Precautions......................................................................................................................................................................................................................1060 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................1060 General Description..............................................................................................................................................................................................................1060 Seat Belt Construction.......................................................................................................................................................................................................1060 Diagnostic Information and Procedures............................................................................................................................................................................................1061 Repair and Inspection Required after Accident................................................................................................................................................................................1061 Repair Instructions..............................................................................................................................................................................................................1062 Front Seat Belt Components...................................................................................................................................................................................................1062 Front Seat Belt Removal and Installation.....................................................................................................................................................................................1063 Front Seat Belt Inspection...................................................................................................................................................................................................1063 Rear Seat Belt Components....................................................................................................................................................................................................1065 Rear Seat Belt Removal and Installation......................................................................................................................................................................................1066 Rear Seat Belt Inspection....................................................................................................................................................................................................1066 Specifications...................................................................................................................................................................................................................1066 Tightening Torque Specifications.............................................................................................................................................................................................1066 Air Bag System.......................................................................................................................................................................................................................1067 Precautions......................................................................................................................................................................................................................1067 Precautions on Service and Diagnosis of Air Bag System.......................................................................................................................................................................1067 Precautions on Handling and Storage of Air Bag System Components.............................................................................................................................................................1067 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................1071 General Description..............................................................................................................................................................................................................1071 Air Bag System Construction..................................................................................................................................................................................................1071 Air Bag System Input / Output Table..........................................................................................................................................................................................1072 Schematic and Routing Diagram....................................................................................................................................................................................................1073 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................1073 Component Location...............................................................................................................................................................................................................1075 Air Bag System Components, Wiring and Connectors Location....................................................................................................................................................................1075 Diagnostic Information and Procedures............................................................................................................................................................................................1076 Air Bag Diagnostic System Check..............................................................................................................................................................................................1076 Air Bag Diagnostic System Check Flow.........................................................................................................................................................................................1076 DTC Table....................................................................................................................................................................................................................1077 DTC Check....................................................................................................................................................................................................................1078 DTC Clearance................................................................................................................................................................................................................1078 Scan Tool Data...............................................................................................................................................................................................................1079 “AIR BAG” Warning Lamp Comes ON Steady.......................................................................................................................................................................................1079 “AIR BAG” Warning Lamp Does Not Come ON......................................................................................................................................................................................1081 “AIR BAG” Warning Lamp Flashes...............................................................................................................................................................................................1082 DTC B1013: SDM fault.........................................................................................................................................................................................................1083 DTC B1014: “AIR BAG” Warning Lamp Circuit Failure............................................................................................................................................................................1083 DTC B1016: Power Source Voltage High.........................................................................................................................................................................................1084 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1086 DTC B1021: Front Air Bag Module Deployed.....................................................................................................................................................................................1088 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed................................................................................................................................................................1088 DTC B1026: Pretensioner Activated............................................................................................................................................................................................1089 DTC B1027: Reusable Number Exceeded..........................................................................................................................................................................................1090 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1090 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1095 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1100 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1105 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1110 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1113 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1116 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1119 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1122 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1124 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1126 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1128 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.........................................................................................................................................1130 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low..........................................................................................................................................1133 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.........................................................................................................................................1136 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit..................................................................................................................................1139 DTC B1071: Forward-Sensor Performance Problem................................................................................................................................................................................1142 DTC B1072: Forward-Sensor Communication Error................................................................................................................................................................................1142 DTC B1073: Forward-Sensor Circuit Short to Ground............................................................................................................................................................................1142 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open.............................................................................................................................................................1144 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem........................................................................................................................................................1146 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error........................................................................................................................................................1146 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground....................................................................................................................................................1146 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open.....................................................................................................................................1148 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID............................................................................................................................................................1150 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High.................................................................................................................................1150 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low..................................................................................................................................1152 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground.................................................................................................................................1154 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit..........................................................................................................................1156 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1159 Repair and Inspection Required after Accident................................................................................................................................................................................1160 Repair Instructions..............................................................................................................................................................................................................1163 Disabling Air Bag System.....................................................................................................................................................................................................1163 Enabling Air Bag System......................................................................................................................................................................................................1164 SDM Removal and Installation.................................................................................................................................................................................................1165 SDM Inspection...............................................................................................................................................................................................................1166 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1166 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1167 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1168 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1169 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1170 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1171 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1172 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1173 Forward-Sensor Removal and Installation......................................................................................................................................................................................1173 Forward-Sensor Inspection....................................................................................................................................................................................................1174 Side-Sensor Removal and Installation.........................................................................................................................................................................................1174 Side-Sensor Inspection.......................................................................................................................................................................................................1175 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................................................................................................1176 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1177 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1187 Specifications...................................................................................................................................................................................................................1188 Tightening Torque Specifications.............................................................................................................................................................................................1188 Special Tools and Equipment......................................................................................................................................................................................................1188 Use of Special Tools.........................................................................................................................................................................................................1188 Recommended Service Material.................................................................................................................................................................................................1190 Special Tool.................................................................................................................................................................................................................1190 Body, Cab and Accessories................................................................................................................................................................................................................1193 Precautions..........................................................................................................................................................................................................................1197 Precautions......................................................................................................................................................................................................................1197 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1197 Precautions for Body Service.................................................................................................................................................................................................1197 Fastener Caution for Body Service............................................................................................................................................................................................1197 Wiring Systems.......................................................................................................................................................................................................................1198 Precautions......................................................................................................................................................................................................................1198 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1198 General Description..............................................................................................................................................................................................................1198 Abbreviations................................................................................................................................................................................................................1198 Wire / Connector Color Symbols...............................................................................................................................................................................................1198 Symbols and Marks............................................................................................................................................................................................................1199 How to Read Connector Layout Diagram.........................................................................................................................................................................................1201 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1202 How to Read Ground Point.....................................................................................................................................................................................................1204 How to Read Power Supply Diagram.............................................................................................................................................................................................1205 How to Read System Circuit Diagram...........................................................................................................................................................................................1205 Connector Layout Diagram.........................................................................................................................................................................................................1207 Connector Layout Diagram.....................................................................................................................................................................................................1207 Engine Compartment...........................................................................................................................................................................................................1207 Instrument Panel.............................................................................................................................................................................................................1213 Door, Roof...................................................................................................................................................................................................................1217 Floor........................................................................................................................................................................................................................1220 Rear.........................................................................................................................................................................................................................1226 Ground Point.....................................................................................................................................................................................................................1227 Ground (earth) Point.........................................................................................................................................................................................................1227 Power Supply Diagram.............................................................................................................................................................................................................1228 Power Supply Diagram.........................................................................................................................................................................................................1228 Fuses and the Protected Parts................................................................................................................................................................................................1230 Fuses in Main Fuse Box (RHD).................................................................................................................................................................................................1230 Fuses in Main Fuse Box (LHD).................................................................................................................................................................................................1230 Individual Circuit Fuse Box No. 1............................................................................................................................................................................................1231 Individual Circuit Fuse Box No. 2 (In J/B)...................................................................................................................................................................................1232 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1234 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1235 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1237 System Circuit Diagram...........................................................................................................................................................................................................1242 System Circuit Diagram.......................................................................................................................................................................................................1242 A-1 Cranking System Circuit Diagram..........................................................................................................................................................................................1243 A-2 Charging System Circuit Diagram..........................................................................................................................................................................................1244 A-3 Ignition System Circuit Diagram..........................................................................................................................................................................................1245 A-4 Cooling System Circuit Diagram...........................................................................................................................................................................................1246 A-5 Engine and A/C Control System Circuit Diagram............................................................................................................................................................................1247 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1252 A-7 Immobilizer System Circuit Diagram.......................................................................................................................................................................................1254 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1255 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1259 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1260 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1261 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1262 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1264 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1266 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1267 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1268 B-9 Keyless Start System Circuit Diagram.....................................................................................................................................................................................1269 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................................................................................................1270 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................................................................................................1271 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................................................................................................1272 D-1 Headlight System Circuit Diagram.........................................................................................................................................................................................1274 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1276 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1277 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1278 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1279 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1280 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1282 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1283 D-9 Headlight Beam Leveling System Circuit Diagram...........................................................................................................................................................................1284 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1285 E-1 Heater System Circuit Diagram............................................................................................................................................................................................1286 E-2 Auto A/C System Circuit Diagram..........................................................................................................................................................................................1288 F-1 Air-Bag System Circuit Diagram...........................................................................................................................................................................................1290 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1292 F-3 Electronic Stability Program System Circuit Diagram......................................................................................................................................................................1294 F-4 Power Steering System Circuit Diagram....................................................................................................................................................................................1296 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1298 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1299 List of Connector................................................................................................................................................................................................................1300 List of Connectors...........................................................................................................................................................................................................1300 C Connector..................................................................................................................................................................................................................1300 D Connector (M16A engine)....................................................................................................................................................................................................1301 E Connector..................................................................................................................................................................................................................1301 G Connector..................................................................................................................................................................................................................1303 J Connector..................................................................................................................................................................................................................1305 K Connector..................................................................................................................................................................................................................1306 L Connector..................................................................................................................................................................................................................1306 M Connector (SPORT model)....................................................................................................................................................................................................1308 O Connector..................................................................................................................................................................................................................1308 R Connector..................................................................................................................................................................................................................1308 Lighting Systems.....................................................................................................................................................................................................................1309 Component Location...............................................................................................................................................................................................................1309 Lighting System Components Location..........................................................................................................................................................................................1309 Interior Light System Location...............................................................................................................................................................................................1310 Diagnostic Information and Procedures............................................................................................................................................................................................1310 Headlight Symptom Diagnosis..................................................................................................................................................................................................1310 DRL System Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1310 Headlight Leveling System Symptom Diagnosis (If Equipped)....................................................................................................................................................................1311 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1311 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1312 Back-Up Light Symptom Diagnosis..............................................................................................................................................................................................1312 Brake Light Symptom Diagnosis................................................................................................................................................................................................1312 Front Fog Light Symptom Diagnosis (If Equipped)..............................................................................................................................................................................1312 Rear Fog Light Symptom Diagnosis (If Equipped)...............................................................................................................................................................................1313 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1313 DRL Operation Inspection (If Equipped).......................................................................................................................................................................................1313 Inspection of DRL Controller and Its Circuits (If Equipped)..................................................................................................................................................................1314 Repair Instructions..............................................................................................................................................................................................................1315 Headlight Housing Removal and Installation...................................................................................................................................................................................1315 Headlight Bulb Replacement...................................................................................................................................................................................................1315 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1316 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1317 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1317 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1318 Hazard Warning Switch Inspection.............................................................................................................................................................................................1318 Brake Light Switch Inspection................................................................................................................................................................................................1319 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1319 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1319 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1319 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1319 License Lamp Assembly Removal and Installation...............................................................................................................................................................................1320 Front Fog Light Assembly Removal and Installation (If Equipped)..............................................................................................................................................................1320 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1321 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1321 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1321 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1322 Headlight Leveling Switch Inspection (If Equipped)...........................................................................................................................................................................1323 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................................................................................................1323 Rear Fog Light Switch Inspection (If Equipped)...............................................................................................................................................................................1323 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1324 Precautions......................................................................................................................................................................................................................1324 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................................................................................................1324 General Description..............................................................................................................................................................................................................1324 CAN Communication System Description.........................................................................................................................................................................................1324 Auto Volume Control System Description (If Equipped).........................................................................................................................................................................1325 Schematic and Routing Diagram....................................................................................................................................................................................................1326 Combination Meter Circuit Diagram............................................................................................................................................................................................1326 Component Location...............................................................................................................................................................................................................1328 Audio System Component Location..............................................................................................................................................................................................1328 Diagnostic Information and Procedures............................................................................................................................................................................................1328 Speedometer and VSS Symptom Diagnosis........................................................................................................................................................................................1328 Tachometer Symptom Diagnosis.................................................................................................................................................................................................1328 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1329 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1329 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1329 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1330 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1330 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1330 A/T Shift Position Indicator Symptom Diagnosis (A/T Model Only)..............................................................................................................................................................1331 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1331 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1331 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1332 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1332 Horn Symptom Diagnosis.......................................................................................................................................................................................................1332 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1333 Clock Symptom Diagnosis (If Equipped)........................................................................................................................................................................................1334 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1334 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1336 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1336 Repair Instructions..............................................................................................................................................................................................................1336 Ignition Switch Removal and Installation.....................................................................................................................................................................................1336 Ignition Switch Inspection...................................................................................................................................................................................................1337 Combination Meter Removal and Installation...................................................................................................................................................................................1337 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1338 Fuel Level Sensor Inspection.................................................................................................................................................................................................1338 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1338 Oil Pressure Switch Inspection...............................................................................................................................................................................................1339 VSS Removal and Installation.................................................................................................................................................................................................1339 VSS Inspection...............................................................................................................................................................................................................1339 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1339 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1339 Parking Brake Switch Inspection..............................................................................................................................................................................................1339 Door Switch (Front / Rear Door) Inspection...................................................................................................................................................................................1340 Rear End Door Switch Inspection..............................................................................................................................................................................................1340 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1340 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1340 Instrument Panel Removal and Installation....................................................................................................................................................................................1341 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1342 Audio Unit Removal and Installation..........................................................................................................................................................................................1342 Front Speaker Removal and Installation.......................................................................................................................................................................................1342 Rear Speaker Removal and Installation........................................................................................................................................................................................1343 GPS Antenna Removal and Installation (If Equipped)...........................................................................................................................................................................1343 Horn Removal and Installation................................................................................................................................................................................................1343 Horn Inspection..............................................................................................................................................................................................................1343 Horn Relay Inspection........................................................................................................................................................................................................1344 Antenna Amplifier Removal and Installation...................................................................................................................................................................................1344 Remote Audio Control Switch Removal and Installation (If Equipped)...........................................................................................................................................................1344 Remote Audio Control Switch Inspection (If Equipped).........................................................................................................................................................................1345 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...............................................................................................................................................................1345 Specifications...................................................................................................................................................................................................................1345 Tightening Torque Specifications.............................................................................................................................................................................................1345 Wipers / Washers.....................................................................................................................................................................................................................1346 Diagnostic Information and Procedures............................................................................................................................................................................................1346 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1346 Rear Wiper and Washer Symptom Diagnosis......................................................................................................................................................................................1346 Repair Instructions..............................................................................................................................................................................................................1347 Wipers and Washers Components................................................................................................................................................................................................1347 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1348 Washer Pump Inspection.......................................................................................................................................................................................................1348 Windshield Wiper Removal and Installation....................................................................................................................................................................................1349 Windshield Wiper Motor Inspection............................................................................................................................................................................................1349 Rear Wiper Removal and Installation..........................................................................................................................................................................................1350 Rear Wiper Motor Inspection..................................................................................................................................................................................................1351 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1352 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1352 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1353 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1354 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1354 Rear Wiper Relay Inspection..................................................................................................................................................................................................1354 Specifications...................................................................................................................................................................................................................1354 Tightening Torque Specifications.............................................................................................................................................................................................1354 Glass / Windows / Mirrors............................................................................................................................................................................................................1355 General Description..............................................................................................................................................................................................................1355 Rear End Door Window Defogger System Description.............................................................................................................................................................................1355 Windshield Construction......................................................................................................................................................................................................1355 Diagnostic Information and Procedures............................................................................................................................................................................................1356 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1356 Power Window Control System Symptom Diagnosis................................................................................................................................................................................1356 Power Door Mirror Control System Symptom Diagnosis...........................................................................................................................................................................1357 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1357 Repair Instructions..............................................................................................................................................................................................................1357 Windshield Removal and Installation..........................................................................................................................................................................................1357 Front Door Window Components.................................................................................................................................................................................................1361 Front Door Glass Removal and Installation....................................................................................................................................................................................1361 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1362 Front Door Window Regulator Inspection.......................................................................................................................................................................................1363 Rear Door Window Components..................................................................................................................................................................................................1363 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1364 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1365 Rear Door Window Regulator Inspection........................................................................................................................................................................................1365 Rear End Door Window Components..............................................................................................................................................................................................1366 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1366 Rear End Door Window Defogger Switch Inspection..............................................................................................................................................................................1367 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1367 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1367 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1368 Power Window Main Switch Inspection..........................................................................................................................................................................................1368 Power Window Sub Switch Inspection...........................................................................................................................................................................................1370 Door Mirror Components.......................................................................................................................................................................................................1370 Door Mirror Removal and Installation.........................................................................................................................................................................................1371 Power Door Mirror Switch Inspection..........................................................................................................................................................................................1371 Power Door Mirror Actuator Inspection........................................................................................................................................................................................1371 Door Mirror Heater Switch Inspection (If Equipped)...........................................................................................................................................................................1372 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1372 Special Tools and Equipment......................................................................................................................................................................................................1372 Recommended Service Material.................................................................................................................................................................................................1372 Security and Locks...................................................................................................................................................................................................................1373 General Description..............................................................................................................................................................................................................1373 Key Coding Construction......................................................................................................................................................................................................1373 Rear End Door Opener System Description......................................................................................................................................................................................1373 Component Location...............................................................................................................................................................................................................1374 Power Door Lock and Keyless Entry System Component Location..................................................................................................................................................................1374 Diagnostic Information and Procedures............................................................................................................................................................................................1375 Power Door Lock System Symptom Diagnosis.....................................................................................................................................................................................1375 Power Door Lock System Operation Inspection..................................................................................................................................................................................1375 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1376 Keyless Entry System Operation Inspection....................................................................................................................................................................................1377 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1377 Rear End Door Opener System Symptom Diagnosis................................................................................................................................................................................1377 Rear End Door Opener System Operation Inspection.............................................................................................................................................................................1377 Repair Instructions..............................................................................................................................................................................................................1378 Front Door Lock Assembly Components..........................................................................................................................................................................................1378 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1379 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1380 Power Door Lock Switch Inspection............................................................................................................................................................................................1380 Door Key Cylinder Switch Inspection..........................................................................................................................................................................................1381 Power Door Lock Actuator Inspection..........................................................................................................................................................................................1381 Rear Door Lock Assembly Components...........................................................................................................................................................................................1382 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1382 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1382 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1383 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1384 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1384 Rear End Door Opener Switch Inspection.......................................................................................................................................................................................1384 Replacement of Transmitter Battery...........................................................................................................................................................................................1385 Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System).................................................................................................................................1385 Keyless Entry Answer Back Function Change- over Procedure (If Equipped)......................................................................................................................................................1386 Keyless Entry Receiver Removal and Installation..............................................................................................................................................................................1386 Keyless Entry Receiver and Its Circuit Inspection............................................................................................................................................................................1387 Specifications...................................................................................................................................................................................................................1388 Tightening Torque Specifications.............................................................................................................................................................................................1388 Special Tools and Equipment......................................................................................................................................................................................................1388 Recommended Service Material.................................................................................................................................................................................................1388 Seats................................................................................................................................................................................................................................1389 Diagnostic Information and Procedures............................................................................................................................................................................................1389 Front Seat Heater Symptom Diagnosis (If Equipped)............................................................................................................................................................................1389 Repair Instructions..............................................................................................................................................................................................................1389 Front Seat Components........................................................................................................................................................................................................1389 Front Seat Removal and Installation..........................................................................................................................................................................................1390 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)................................................................................................................................................1390 Front Seat Heater Wire Inspection (If Equipped)..............................................................................................................................................................................1390 Rear Seat Components.........................................................................................................................................................................................................1391 Rear Seat Removal and Installation...........................................................................................................................................................................................1392 Specifications...................................................................................................................................................................................................................1392 Tightening Torque Specifications.............................................................................................................................................................................................1392 Interior Trim........................................................................................................................................................................................................................1393 Repair Instructions..............................................................................................................................................................................................................1393 Floor Carpet Removal and Installation........................................................................................................................................................................................1393 Head Lining Removal and Installation.........................................................................................................................................................................................1393 Console Box Components.......................................................................................................................................................................................................1395 Specifications...................................................................................................................................................................................................................1395 Tightening Torque Specifications.............................................................................................................................................................................................1395 Hood / Fenders / Doors...............................................................................................................................................................................................................1396 Repair Instructions..............................................................................................................................................................................................................1396 Hood Removal and Installation................................................................................................................................................................................................1396 Hood Inspection and Adjustment...............................................................................................................................................................................................1396 Front Fender Components......................................................................................................................................................................................................1397 Front Fender Removal and Installation........................................................................................................................................................................................1397 Front Door Assembly Components...............................................................................................................................................................................................1398 Front Door Assembly Removal and Installation.................................................................................................................................................................................1398 Rear Door Assembly Components................................................................................................................................................................................................1399 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1400 Rear End Door Assembly Components............................................................................................................................................................................................1400 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1400 Specifications...................................................................................................................................................................................................................1402 Tightening Torque Specifications.............................................................................................................................................................................................1402 Special Tools and Equipment......................................................................................................................................................................................................1402 Recommended Service Material.................................................................................................................................................................................................1402 Body Structure.......................................................................................................................................................................................................................1403 Repair Instructions..............................................................................................................................................................................................................1403 Front Bumper and Rear Bumper Components......................................................................................................................................................................................1403 Cowl Top Components..........................................................................................................................................................................................................1404 Specifications...................................................................................................................................................................................................................1405 Body Dimensions..............................................................................................................................................................................................................1405 Panel Clearance..............................................................................................................................................................................................................1412 Paint / Coatings.....................................................................................................................................................................................................................1413 General Description..............................................................................................................................................................................................................1413 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1413 Plastic Parts Finishing......................................................................................................................................................................................................1413 Component Location...............................................................................................................................................................................................................1414 Sealant Application Areas....................................................................................................................................................................................................1414 Under Coating Application Areas..............................................................................................................................................................................................1419 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1421 Exterior Trim........................................................................................................................................................................................................................1422 Repair Instructions..............................................................................................................................................................................................................1422 Roof Molding Components......................................................................................................................................................................................................1422 Splash Guard (If Equipped) Components........................................................................................................................................................................................1423 Control Systems..........................................................................................................................................................................................................................1425 Precautions..........................................................................................................................................................................................................................1427 Precautions......................................................................................................................................................................................................................1427 Precautions for Control Systems..............................................................................................................................................................................................1427 Body Electrical Control System.......................................................................................................................................................................................................1428 Precautions......................................................................................................................................................................................................................1428 Precautions in Diagnosing Trouble............................................................................................................................................................................................1428 General Description..............................................................................................................................................................................................................1428 BCM General Description......................................................................................................................................................................................................1428 CAN Communication System Description.........................................................................................................................................................................................1428 Theft Deterrent Light........................................................................................................................................................................................................1429 Security Alarm Description (If Equipped).....................................................................................................................................................................................1429 Schematic and Routing Diagram....................................................................................................................................................................................................1430 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1430 Connector Layout Diagram of BCM and Junction Block Assembly..................................................................................................................................................................1433 Component Location...............................................................................................................................................................................................................1434 BCM and Related System Component Location....................................................................................................................................................................................1434 Diagnostic Information and Procedures............................................................................................................................................................................................1435 BCM Self-Diagnosis Function..................................................................................................................................................................................................1435 Body Electrical Control System Check.........................................................................................................................................................................................1436 Scan Tool Data...............................................................................................................................................................................................................1438 DTC Table....................................................................................................................................................................................................................1440 DTC Check....................................................................................................................................................................................................................1440 DTC Clearance................................................................................................................................................................................................................1442 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1442 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1444 DTC B1141 / DTC B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction..............................................................................................................1444 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1446 DTC B1157 (No. 1157): Air Bag Deployment Signal Input........................................................................................................................................................................1447 DTC B1170 (No. 1170): EEPROM Access Error....................................................................................................................................................................................1447 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module..................................................................................................................................1448 DTC U1073 (No. 1073): Control Module Communication Bus Off...................................................................................................................................................................1450 DTC U1100 (No. 1100): Lost Communication with ECM............................................................................................................................................................................1451 DTC U1101 (No. 1101): Lost Communication with TCM............................................................................................................................................................................1452 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1453 Inspection of BCM and its Circuits...........................................................................................................................................................................................1454 Repair Instructions..............................................................................................................................................................................................................1462 BCM (Included in Junction Block Assembly) Removal and Installation...........................................................................................................................................................1462 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1462 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1462 Security Alarm Mode Selection Procedure (If Equipped)........................................................................................................................................................................1462 Special Tools and Equipment......................................................................................................................................................................................................1463 Special Tool.................................................................................................................................................................................................................1463 Immobilizer Control System...........................................................................................................................................................................................................1464 Precautions......................................................................................................................................................................................................................1464 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1464 Precaution in Replacing ECM..................................................................................................................................................................................................1464 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1464 General Description..............................................................................................................................................................................................................1465 Immobilizer Control System Introduction......................................................................................................................................................................................1465 Immobilizer Control System Components Location...............................................................................................................................................................................1466 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................................................................................................1466 Schematic and Routing Diagram....................................................................................................................................................................................................1467 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1467 Diagnostic Information and Procedures............................................................................................................................................................................................1468 Immobilizer Control System Check.............................................................................................................................................................................................1468 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1469 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1469 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1469 Scan Tool Data...............................................................................................................................................................................................................1470 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1470 Immobilizer Indicator Lamp Remains ON after Engine Starts....................................................................................................................................................................1471 DTC P1614: Transponder Response Error........................................................................................................................................................................................1472 DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only).....................................................................................................................................1473 DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only).................................................................................................................................1474 DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)......................................................................................1475 DTC P1621: Immobilizer Communication Line Error..............................................................................................................................................................................1476 DTC P1622: EEPROM Reading / Writing Error....................................................................................................................................................................................1477 DTC P1623: Unregistered Transponder..........................................................................................................................................................................................1477 DTC P1625: Immobilizer Antenna Error.........................................................................................................................................................................................1478 DTC P1636: Immobilizer Information Registration Failure......................................................................................................................................................................1478 DTC P1638: Immobilizer Information Mismatched................................................................................................................................................................................1479 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1480 Repair Instructions..............................................................................................................................................................................................................1482 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1482 Registration of the Ignition Key.............................................................................................................................................................................................1482 Procedure after ECM Replacement..............................................................................................................................................................................................1482 Special Tools and Equipment......................................................................................................................................................................................................1483 Special Tool.................................................................................................................................................................................................................1483 Keyless Start System.................................................................................................................................................................................................................1484 General Description..............................................................................................................................................................................................................1484 Keyless Start System Description.............................................................................................................................................................................................1484 Parts and Functions..........................................................................................................................................................................................................1485 Keyless Engine Start Function................................................................................................................................................................................................1486 Door Lock Function of Keyless Start System...................................................................................................................................................................................1487 Operation Area of Remote Controller..........................................................................................................................................................................................1488 Alarm Function...............................................................................................................................................................................................................1489 CAN Communication of Keyless Start System....................................................................................................................................................................................1489 Schematic and Routing Diagram....................................................................................................................................................................................................1490 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1490 Diagnostic Information and Procedures............................................................................................................................................................................................1491 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1491 Self-Diagnosis Function......................................................................................................................................................................................................1491 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1491 Keyless Start System Check...................................................................................................................................................................................................1491 Customer Questionnaire (Example).............................................................................................................................................................................................1492 Key Indicator Lamp Check.....................................................................................................................................................................................................1493 DTC Check....................................................................................................................................................................................................................1493 DTC Table....................................................................................................................................................................................................................1494 DTC Clearance................................................................................................................................................................................................................1495 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1496 Keyless Start System Operation Inspection....................................................................................................................................................................................1497 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1497 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1498 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1502 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.).....................................................................................................................1503 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1505 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1506 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1507 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)..........................................................................................................1507 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1508 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1510 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1512 Repair Instructions..............................................................................................................................................................................................................1514 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1514 Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection..............................................................................................................................................1515 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1515 Steering Lock Unit Inspection................................................................................................................................................................................................1515 Front Door Lock Switch Inspection............................................................................................................................................................................................1515 Keyless Start Control Module Removal and Installation........................................................................................................................................................................1516 Remote Controller Inspection.................................................................................................................................................................................................1516 Replacement of Remote Controller Battery.....................................................................................................................................................................................1516 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1517 COPYRIGHT................................................................................................................................................................................................................................1519 BOOKCOVER_VOL1...........................................................................................................................................................................................................................1520 BOOKCOVER_VOL2...........................................................................................................................................................................................................................1521
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