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Suzuki RS416 Swift Service Manual (Vol 1&2) – PDF DOWNLOAD
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Description
Suzuki RS416 Swift Service Manual (Vol 1&2) – PDF DOWNLOAD
FILE DETAILS:
Suzuki RS416 Swift Service Manual (Vol 1&2) – PDF DOWNLOAD
Language : English
Pages : 1501
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki RS416 Swift Service Manual (Vol 1&2) – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and reassembly of major components (Unit Repair-Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
- VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10).
Applicable Model:
SWIFT (RS416) produced at KOSAI plant in Japan with the following vehicle identification numbers (VINs). - The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work.
- Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki RS416 Swift Service Manual (Vol 1&2) – PDF DOWNLOAD
TOP...................................................................................................................................................................................................................................... 0 MANUAL LIST.............................................................................................................................................................................................................................. 0 IMPORTANT................................................................................................................................................................................................................................ 1 FOREWORD................................................................................................................................................................................................................................. 3 TABLE OF CONTENTS........................................................................................................................................................................................................................ 5 Precautions.............................................................................................................................................................................................................................. 7 Precautions.......................................................................................................................................................................................................................... 8 Precautions...................................................................................................................................................................................................................... 8 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System............................................................................................................................................. 8 General Precautions.......................................................................................................................................................................................................... 11 Warning for Wheel (with tire) Removal........................................................................................................................................................................................ 14 Warning for Handling Emergency Flat Tire Repair Kit.......................................................................................................................................................................... 14 Precautions for Catalytic Converter.......................................................................................................................................................................................... 14 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 14 Precaution for CAN Communication System...................................................................................................................................................................................... 14 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 Precaution for Vehicle Equipped with ESP‚ System............................................................................................................................................................................. 18 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.............................................................................................................................................................................................................. 35 Accessory Drive Belt Inspection.............................................................................................................................................................................................. 35 Accessory Drive Belt Replacement............................................................................................................................................................................................. 36 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 36 Engine Oil and Filter Change................................................................................................................................................................................................. 36 Engine Coolant Change........................................................................................................................................................................................................ 37 Exhaust System Inspection.................................................................................................................................................................................................... 38 Spark Plug Replacement....................................................................................................................................................................................................... 38 Air Cleaner Filter Inspection................................................................................................................................................................................................ 38 Air Cleaner Filter Replacement............................................................................................................................................................................................... 38 Fuel Lines and Connections Inspection........................................................................................................................................................................................ 38 Fuel Filter Replacement...................................................................................................................................................................................................... 39 Fuel Tank Inspection......................................................................................................................................................................................................... 39 PCV Valve Inspection......................................................................................................................................................................................................... 39 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 39 Brake Discs and Pads Inspection.............................................................................................................................................................................................. 39 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 39 Brake Fluid Inspection....................................................................................................................................................................................................... 40 Brake Fluid Replacement...................................................................................................................................................................................................... 40 Brake Lever and Cable Inspection............................................................................................................................................................................................. 40 Clutch Fluid Inspection...................................................................................................................................................................................................... 40 Tires Inspection............................................................................................................................................................................................................. 41 Wheel Discs Inspection....................................................................................................................................................................................................... 41 Wheel Bearing Inspection..................................................................................................................................................................................................... 41 Suspension System Inspection................................................................................................................................................................................................. 41 Steering System Inspection................................................................................................................................................................................................... 42 Drive Shaft (Axle) Boots Inspection.......................................................................................................................................................................................... 42 Manual Transaxle Oil Inspection.............................................................................................................................................................................................. 42 Manual Transaxle Oil Replacement............................................................................................................................................................................................. 42 Automatic Transaxle Fluid Level Inspection................................................................................................................................................................................... 43 Automatic Transaxle Fluid Replacement........................................................................................................................................................................................ 43 Automatic Transaxle Fluid Cooler Hose Inspection............................................................................................................................................................................. 43 All Latches, Hinges and Locks Inspection..................................................................................................................................................................................... 43 HVAC Air Filter (If Equipped) Inspection..................................................................................................................................................................................... 44 HVAC Air Filter (If Equipped) Replacement.................................................................................................................................................................................... 44 Final Inspection for Maintenance Service..................................................................................................................................................................................... 44 Specifications................................................................................................................................................................................................................... 45 Tightening Torque Specifications............................................................................................................................................................................................. 45 Special Tools and Equipment...................................................................................................................................................................................................... 45 Recommended Fluids and Lubricants............................................................................................................................................................................................ 45 Special Tool................................................................................................................................................................................................................. 46 Engine................................................................................................................................................................................................................................... 47 Precautions.......................................................................................................................................................................................................................... 52 Precautions...................................................................................................................................................................................................................... 52 Precautions for Engine....................................................................................................................................................................................................... 52 Engine General Information and Diagnosis............................................................................................................................................................................................. 53 Precautions...................................................................................................................................................................................................................... 53 Precautions on Engine Service................................................................................................................................................................................................ 53 Precaution on On-Board Diagnostic (OBD) System............................................................................................................................................................................... 53 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 53 Precautions of ECM Circuit Inspection........................................................................................................................................................................................ 54 Precautions of Electric Throttle Body System Calibration..................................................................................................................................................................... 54 General Description.............................................................................................................................................................................................................. 54 Statement on Cleanliness and Care............................................................................................................................................................................................ 54 Engine Diagnosis General Description......................................................................................................................................................................................... 55 On-Board Diagnostic System Description....................................................................................................................................................................................... 55 Data Link Connector (DLC).................................................................................................................................................................................................... 58 Engine and Emission Control System Description............................................................................................................................................................................... 58 CAN Communication System Description......................................................................................................................................................................................... 59 Air Intake System Description................................................................................................................................................................................................ 61 Description of Electric Throttle Body System................................................................................................................................................................................. 61 Description of Electric Throttle Body System Calibration..................................................................................................................................................................... 62 Fuel Cut Control Description................................................................................................................................................................................................. 62 Generator Control System Description......................................................................................................................................................................................... 63 Electronic Control System Description........................................................................................................................................................................................ 64 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 70 Schematic and Routing Diagram.................................................................................................................................................................................................... 71 Engine and Emission Control System Diagram................................................................................................................................................................................... 71 Component Location............................................................................................................................................................................................................... 73 Electronic Control System Components Location................................................................................................................................................................................ 73 Diagnostic Information and Procedures............................................................................................................................................................................................ 74 Engine and Emission Control System Check..................................................................................................................................................................................... 74 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 77 DTC Check.................................................................................................................................................................................................................... 78 DTC Clearance................................................................................................................................................................................................................ 79 DTC Table.................................................................................................................................................................................................................... 79 Fail-Safe Table.............................................................................................................................................................................................................. 83 Scan Tool Data............................................................................................................................................................................................................... 85 Visual Inspection............................................................................................................................................................................................................ 89 Engine Basic Inspection...................................................................................................................................................................................................... 90 Engine Symptom Diagnosis..................................................................................................................................................................................................... 93 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)..................................................................................................................................... 99 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 100 DTC P0010: “A” Camshaft Position Actuator Circuit............................................................................................................................................................................ 101 DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System Performance / - Retarded........................................................................................................................... 104 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 106 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 108 DTC P0101: Mass or Volume Air Flow Circuit Range / Performance............................................................................................................................................................... 110 DTC P0102: Mass or Volume Air Flow Circuit Low Input......................................................................................................................................................................... 113 DTC P0103: Mass or Volume Air Flow Circuit High Input........................................................................................................................................................................ 115 DTC P0106: Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance...................................................................................................................................... 116 DTC P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low Input................................................................................................................................................ 118 DTC P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High Input............................................................................................................................................... 119 DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance....................................................................................................................................................... 121 DTC P0112: Intake Air Temperature Sensor 1 Circuit Low....................................................................................................................................................................... 124 DTC P0113: Intake Air Temperature 1 Sensor Circuit High...................................................................................................................................................................... 126 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 128 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 131 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 133 DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low.................................................................................................................................................. 135 DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit High................................................................................................................................................. 137 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................................................................................................ 140 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 143 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).......................................................................................................................................................... 144 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 146 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 149 DTC P0171 / P0172: Fuel System Too Lean / Rich............................................................................................................................................................................... 150 DTC P0222: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit Low................................................................................................................................................... 152 DTC P0223: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit High.................................................................................................................................................. 154 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected.................................................................. 157 DTC P0327 / P0328: Knock Sensor 1 Circuit Low / High......................................................................................................................................................................... 159 DTC P0335: Crankshaft Position (CKP) Sensor “A” Circuit...................................................................................................................................................................... 161 DTC P0340: Camshaft Position (CMP) Sensor “A” Circuit........................................................................................................................................................................ 163 DTC P0350: Ignition Coil Primary / Secondary Circuit......................................................................................................................................................................... 166 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 168 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 170 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 172 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 174 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 176 DTC P0500: Vehicle Speed Sensor “A” Malfunction.............................................................................................................................................................................. 180 DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low................................................................................................................................................................... 182 DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit High.................................................................................................................................................................. 184 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance.................................................................................... 186 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 187 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 188 DTC P0620: Generator Control Circuit......................................................................................................................................................................................... 189 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High............................................................................................................................................................... 191 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High........................................................................................................................................................... 193 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 195 DTC P1603: TCM Trouble Code Detected......................................................................................................................................................................................... 196 DTC P1674: CAN Communication (Bus Off Error)................................................................................................................................................................................. 197 DTC P1676: CAN Communication (Reception Error for TCM)....................................................................................................................................................................... 200 DTC P1678: CAN Communication (Reception Error for BCM)....................................................................................................................................................................... 201 DTC P1685: CAN Communication (Reception Error for ABS/ESP‚ Control Module)................................................................................................................................................... 202 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance....................................................................................................................................................... 204 DTC P2102: Throttle Actuator Control Motor Circuit Low....................................................................................................................................................................... 206 DTC P2103: Throttle Actuator Control Motor Circuit High...................................................................................................................................................................... 207 DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed.................................................................................................................................................... 208 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance....................................................................................................................................................... 209 DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input............................................................................................................................................ 211 DTC P2123: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit High Input........................................................................................................................................... 213 DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input............................................................................................................................................... 216 DTC P2128: Throttle / Pedal Position Sensor / Switch “E” (Sub) Circuit High Input............................................................................................................................................ 218 DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage Correlation................................................................................................................................ 220 DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage Correlation................................................................................................................................ 223 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 225 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 227 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 246 Fuel Injector Circuit Check.................................................................................................................................................................................................. 250 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 252 Fuel Pressure Check.......................................................................................................................................................................................................... 255 A/C System Circuits Check.................................................................................................................................................................................................... 257 Electric Load Signal Circuit Check........................................................................................................................................................................................... 261 Radiator Cooling Fan Low Speed Control System Check.......................................................................................................................................................................... 263 Radiator Cooling Fan High Speed Control System Check......................................................................................................................................................................... 265 Repair Instructions.............................................................................................................................................................................................................. 268 Idle Speed and IAC Throttle Valve Opening Inspection......................................................................................................................................................................... 268 Special Tools and Equipment...................................................................................................................................................................................................... 269 Special Tool................................................................................................................................................................................................................. 269 Aux. Emission Control Devices........................................................................................................................................................................................................ 270 Diagnostic Information and Procedures............................................................................................................................................................................................ 270 EGR System Inspection........................................................................................................................................................................................................ 270 Repair Instructions.............................................................................................................................................................................................................. 270 EVAP Canister Purge Inspection............................................................................................................................................................................................... 270 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 271 Vacuum Passage Inspection.................................................................................................................................................................................................... 272 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................................................................................................... 272 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 272 EVAP Canister Inspection..................................................................................................................................................................................................... 273 EGR Valve Removal and Installation........................................................................................................................................................................................... 273 EGR Valve Inspection......................................................................................................................................................................................................... 273 PCV Hose Inspection.......................................................................................................................................................................................................... 273 PCV Valve Inspection......................................................................................................................................................................................................... 274 Special Tools and Equipment...................................................................................................................................................................................................... 274 Special Tool................................................................................................................................................................................................................. 274 Engine Electrical Devices............................................................................................................................................................................................................ 275 Repair Instructions.............................................................................................................................................................................................................. 275 ECM Removal and Installation................................................................................................................................................................................................. 275 MAP Sensor Inspection........................................................................................................................................................................................................ 276 Electric Throttle Body Assembly On-Vehicle Inspection........................................................................................................................................................................ 276 Electric Throttle Body System Calibration.................................................................................................................................................................................... 279 APP Sensor Assembly On-Vehicle Inspection.................................................................................................................................................................................... 279 APP Sensor Assembly Removal and Installation................................................................................................................................................................................. 279 APP Sensor Assembly Inspection............................................................................................................................................................................................... 280 ECT Sensor Removal and Installation.......................................................................................................................................................................................... 280 ECT Sensor Inspection........................................................................................................................................................................................................ 281 HO2S-1 and HO2S-2 Heater On-Vehicle Inspection............................................................................................................................................................................... 281 HO2S-1 and HO2S-2 Removal and Installation................................................................................................................................................................................... 281 CMP Sensor Removal and Installation.......................................................................................................................................................................................... 282 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 282 CKP Sensor Removal and Installation.......................................................................................................................................................................................... 283 CKP Sensor Inspection........................................................................................................................................................................................................ 283 Knock Sensor Removal and Installation........................................................................................................................................................................................ 284 Main Relay, Fuel Pump Relay and Starting Motor Control Relay Inspection...................................................................................................................................................... 284 MAF and IAT Sensor On-Vehicle Inspection..................................................................................................................................................................................... 285 MAF and IAT Sensor Removal and Installation.................................................................................................................................................................................. 285 MAF and IAT Sensor Inspection................................................................................................................................................................................................ 286 Electric Load Current Sensor On-Vehicle Inspection........................................................................................................................................................................... 286 Specifications................................................................................................................................................................................................................... 287 Tightening Torque Specifications............................................................................................................................................................................................. 287 Engine Mechanical.................................................................................................................................................................................................................... 288 General Description.............................................................................................................................................................................................................. 288 Engine Construction Description.............................................................................................................................................................................................. 288 Camshaft Position Control (VVT Variable Valve Timing) System Description..................................................................................................................................................... 289 Diagnostic Information and Procedures............................................................................................................................................................................................ 291 Compression Check............................................................................................................................................................................................................ 291 Engine Vacuum Check.......................................................................................................................................................................................................... 292 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 293 Repair Instructions.............................................................................................................................................................................................................. 296 Air Cleaner Components....................................................................................................................................................................................................... 296 Air Cleaner Element Removal and Installation................................................................................................................................................................................. 296 Air Cleaner Element Inspection and Cleaning.................................................................................................................................................................................. 297 Cylinder Head Cover Removal and Installation................................................................................................................................................................................. 297 Throttle Body and Intake Manifold Components................................................................................................................................................................................. 299 Throttle Body On-Vehicle Inspection.......................................................................................................................................................................................... 300 Electric Throttle Body Assembly Removal and Installation..................................................................................................................................................................... 300 Throttle Body Cleaning....................................................................................................................................................................................................... 301 Intake Manifold Removal and Installation..................................................................................................................................................................................... 301 Engine Mountings Components.................................................................................................................................................................................................. 303 Engine Assembly Removal and Installation..................................................................................................................................................................................... 304 Timing Chain Cover Components................................................................................................................................................................................................ 307 Timing Chain Cover Removal and Installation.................................................................................................................................................................................. 308 Timing Chain Cover Inspection................................................................................................................................................................................................ 310 Oil Control Valve Removal and Installation................................................................................................................................................................................... 310 Oil Control Valve Inspection................................................................................................................................................................................................. 311 Timing Chain and Chain Tensioner Components.................................................................................................................................................................................. 311 Timing Chain and Chain Tensioner Removal and Installation.................................................................................................................................................................... 312 Timing Chain and Chain Tensioner Inspection.................................................................................................................................................................................. 314 Camshaft, Tappet and Shim Components......................................................................................................................................................................................... 315 Camshaft, Tappet and Shim Removal and Installation........................................................................................................................................................................... 316 Camshaft, Tappet and Shim Inspection......................................................................................................................................................................................... 318 Valves and Cylinder Head Components.......................................................................................................................................................................................... 321 Valves and Cylinder Head Removal and Installation............................................................................................................................................................................ 322 Valves and Cylinder Head Disassembly and Assembly............................................................................................................................................................................ 324 Valves and Valve Guides Inspection........................................................................................................................................................................................... 327 Cylinder Head Inspection..................................................................................................................................................................................................... 329 Valve Spring Inspection...................................................................................................................................................................................................... 330 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................................................................................................. 331 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................................................................................................ 332 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................................................................................................ 333 Cylinders, Pistons and Piston Rings Inspection............................................................................................................................................................................... 334 Piston Pins and Connecting Rods Inspection................................................................................................................................................................................... 336 Crank Pin and Connecting Rod Bearings Inspection............................................................................................................................................................................. 337 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................................................................................................... 340 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................................................................................................ 341 Crankshaft Inspection........................................................................................................................................................................................................ 344 Main Bearings Inspection..................................................................................................................................................................................................... 346 Sensor Plate Inspection...................................................................................................................................................................................................... 350 Rear Oil Seal Inspection..................................................................................................................................................................................................... 350 Flywheel Inspection.......................................................................................................................................................................................................... 350 Cylinder Block Inspection.................................................................................................................................................................................................... 350 Specifications................................................................................................................................................................................................................... 351 Tightening Torque Specifications............................................................................................................................................................................................. 351 Special Tools and Equipment...................................................................................................................................................................................................... 353 Recommended Service Material................................................................................................................................................................................................. 353 Special Tool................................................................................................................................................................................................................. 353 Engine Lubrication System............................................................................................................................................................................................................ 355 General Description.............................................................................................................................................................................................................. 355 Engine Lubrication Description............................................................................................................................................................................................... 355 Diagnostic Information and Procedures............................................................................................................................................................................................ 356 Oil Pressure Check........................................................................................................................................................................................................... 356 Repair Instructions.............................................................................................................................................................................................................. 357 Heat Exchanger Components.................................................................................................................................................................................................... 357 Heat Exchanger On-Vehicle Inspection......................................................................................................................................................................................... 358 Heat Exchanger Removal and Installation...................................................................................................................................................................................... 358 Oil Pan and Oil Pump Strainer Components..................................................................................................................................................................................... 359 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................................................................................................... 359 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................................................................................................... 361 Oil Pump Components.......................................................................................................................................................................................................... 362 Oil Pump Removal and Installation............................................................................................................................................................................................ 362 Oil Pump Disassembly and Reassembly.......................................................................................................................................................................................... 362 Oil Pump Inspection.......................................................................................................................................................................................................... 363 Specifications................................................................................................................................................................................................................... 365 Tightening Torque Specifications............................................................................................................................................................................................. 365 Special Tools and Equipment...................................................................................................................................................................................................... 365 Recommended Service Material................................................................................................................................................................................................. 365 Special Tool................................................................................................................................................................................................................. 365 Engine Cooling System................................................................................................................................................................................................................ 366 General Description.............................................................................................................................................................................................................. 366 Cooling System Description................................................................................................................................................................................................... 366 Coolant Description.......................................................................................................................................................................................................... 366 Schematic and Routing Diagram.................................................................................................................................................................................................... 367 Coolant Circulation.......................................................................................................................................................................................................... 367 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........................................................................................................................................................................ 372 Thermostat Removal and Installation.......................................................................................................................................................................................... 373 Thermostat Inspection........................................................................................................................................................................................................ 373 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................................................................................................................. 374 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 374 Radiator Cooling Fan Removal and Installation................................................................................................................................................................................ 375 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 375 Radiator Removal and Installation............................................................................................................................................................................................ 375 Water Pump Removal and Installation.......................................................................................................................................................................................... 376 Water Pump Inspection........................................................................................................................................................................................................ 376 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............................................................................................................................................................................................ 379 Fuel Pressure Inspection..................................................................................................................................................................................................... 379 Fuel Cut Operation Inspection................................................................................................................................................................................................ 380 Repair Instructions.............................................................................................................................................................................................................. 381 Fuel System Components....................................................................................................................................................................................................... 381 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 382 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 384 Fuel Leakage Check Procedure................................................................................................................................................................................................. 384 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 384 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 384 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 385 Fuel Injector Removal and Installation....................................................................................................................................................................................... 385 Fuel Injector Inspection..................................................................................................................................................................................................... 386 Fuel Filler Cap Inspection................................................................................................................................................................................................... 387 Fuel Tank Inlet Valve Removal and Installation............................................................................................................................................................................... 388 Fuel Tank Inlet Valve Inspection............................................................................................................................................................................................. 389 Fuel Tank Removal and Installation........................................................................................................................................................................................... 389 Fuel Tank Inspection......................................................................................................................................................................................................... 390 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 391 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 391 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 391 Main Fuel Level Sensor Removal and Installation.............................................................................................................................................................................. 392 Fuel Pump Inspection......................................................................................................................................................................................................... 393 Specifications................................................................................................................................................................................................................... 393 Tightening Torque Specifications............................................................................................................................................................................................. 393 Special Tools and Equipment...................................................................................................................................................................................................... 394 Special Tool................................................................................................................................................................................................................. 394 Ignition System...................................................................................................................................................................................................................... 395 General Description.............................................................................................................................................................................................................. 395 Ignition System Construction................................................................................................................................................................................................. 395 Schematic and Routing Diagram.................................................................................................................................................................................................... 396 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 396 Component Location............................................................................................................................................................................................................... 397 Ignition System Components Location.......................................................................................................................................................................................... 397 Diagnostic Information and Procedures............................................................................................................................................................................................ 398 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 398 Reference Waveform of Ignition System........................................................................................................................................................................................ 398 Ignition System Check........................................................................................................................................................................................................ 398 Ignition Spark Test.......................................................................................................................................................................................................... 400 Repair Instructions.............................................................................................................................................................................................................. 400 High-Tension Cord Removal and Installation................................................................................................................................................................................... 400 High-Tension Cord Inspection................................................................................................................................................................................................. 401 Spark Plug Removal and Installation.......................................................................................................................................................................................... 401 Spark Plug Inspection........................................................................................................................................................................................................ 401 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................................................................................................... 402 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................................................................................................ 402 Ignition Timing Inspection................................................................................................................................................................................................... 402 Specifications................................................................................................................................................................................................................... 403 Tightening Torque Specifications............................................................................................................................................................................................. 403 Special Tools and Equipment...................................................................................................................................................................................................... 403 Special Tool................................................................................................................................................................................................................. 403 Starting System...................................................................................................................................................................................................................... 404 Schematic and Routing Diagram.................................................................................................................................................................................................... 404 Cranking System Circuit Diagram.............................................................................................................................................................................................. 404 Diagnostic Information and Procedures............................................................................................................................................................................................ 404 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 404 Cranking System Test......................................................................................................................................................................................................... 406 Repair Instructions.............................................................................................................................................................................................................. 407 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 407 Starting Motor Components.................................................................................................................................................................................................... 408 Starting Motor Inspection.................................................................................................................................................................................................... 409 Specifications................................................................................................................................................................................................................... 412 Cranking System Specifications............................................................................................................................................................................................... 412 Tightening Torque Specifications............................................................................................................................................................................................. 412 Special Tools and Equipment...................................................................................................................................................................................................... 412 Recommended Service Material................................................................................................................................................................................................. 412 Charging System...................................................................................................................................................................................................................... 413 General Description.............................................................................................................................................................................................................. 413 Battery Description.......................................................................................................................................................................................................... 413 Generator Description........................................................................................................................................................................................................ 414 Diagnostic Information and Procedures............................................................................................................................................................................................ 416 Battery Inspection........................................................................................................................................................................................................... 416 Generator Symptom Diagnosis.................................................................................................................................................................................................. 416 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 417 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 418 Repair Instructions.............................................................................................................................................................................................................. 418 Jump Starting in Case of Emergency........................................................................................................................................................................................... 418 Battery Dismounting and Remounting........................................................................................................................................................................................... 419 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.......................................................................................................................................................... 419 Water Pump / Generator Drive Belt Removal and Installation................................................................................................................................................................... 420 Generator Unit Components.................................................................................................................................................................................................... 421 Generator Dismounting and Remounting......................................................................................................................................................................................... 421 Generator Components......................................................................................................................................................................................................... 422 Generator Inspection......................................................................................................................................................................................................... 423 Specifications................................................................................................................................................................................................................... 425 Charging System Specifications............................................................................................................................................................................................... 425 Tightening Torque Specifications............................................................................................................................................................................................. 425 Exhaust System....................................................................................................................................................................................................................... 426 General Description.............................................................................................................................................................................................................. 426 Exhaust System Description................................................................................................................................................................................................... 426 Diagnostic Information and Procedures............................................................................................................................................................................................ 426 Exhaust System Check......................................................................................................................................................................................................... 426 Repair Instructions.............................................................................................................................................................................................................. 427 Exhaust System Components.................................................................................................................................................................................................... 427 Exhaust Manifold Removal and Installation.................................................................................................................................................................................... 428 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 429 Specifications................................................................................................................................................................................................................... 430 Tightening Torque Specifications............................................................................................................................................................................................. 430 Suspension............................................................................................................................................................................................................................... 431 Precautions.......................................................................................................................................................................................................................... 433 Precautions...................................................................................................................................................................................................................... 433 Precautions on Suspension.................................................................................................................................................................................................... 433 Suspension General Diagnosis......................................................................................................................................................................................................... 434 Diagnostic Information and Procedures............................................................................................................................................................................................ 434 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 434 Front Suspension..................................................................................................................................................................................................................... 436 General Description.............................................................................................................................................................................................................. 436 Front Suspension Construction................................................................................................................................................................................................ 436 Front Wheel Alignment Construction........................................................................................................................................................................................... 437 Repair Instructions.............................................................................................................................................................................................................. 437 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 437 Front Strut Assembly Components.............................................................................................................................................................................................. 439 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 439 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 441 Front Strut Assembly Check................................................................................................................................................................................................... 442 Front Wheel Hub and Steering Knuckle Components.............................................................................................................................................................................. 443 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................................................................................................. 443 Front Wheel Hub, Disc, Nut and Bearing Check................................................................................................................................................................................. 447 Suspension Control Arm / Bushing Removal and Installation.................................................................................................................................................................... 447 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 448 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 449 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 449 Suspension Control Arm Joint Check........................................................................................................................................................................................... 449 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 450 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 450 Front Suspension Frame Check................................................................................................................................................................................................. 454 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 454 Front Suspension Fasteners Check............................................................................................................................................................................................. 454 Specifications................................................................................................................................................................................................................... 455 Tightening Torque Specifications............................................................................................................................................................................................. 455 Special Tools and Equipment...................................................................................................................................................................................................... 456 Special Tool................................................................................................................................................................................................................. 456 Rear Suspension...................................................................................................................................................................................................................... 457 General Description.............................................................................................................................................................................................................. 457 Rear Suspension Construction................................................................................................................................................................................................. 457 Repair Instructions.............................................................................................................................................................................................................. 458 Rear Wheel Alignment Inspection.............................................................................................................................................................................................. 458 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 458 Rear Shock Absorber Inspection............................................................................................................................................................................................... 459 Rear Shock Absorber Bush Removal and Installation............................................................................................................................................................................ 460 Rear Shock Absorber Bush Inspection.......................................................................................................................................................................................... 460 Rear Coil Spring Removal and Installation.................................................................................................................................................................................... 460 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................................................................................................. 461 Spring Upper Seat and Lower Seat Removal and Installation.................................................................................................................................................................... 462 Rear Axle Removal and Installation........................................................................................................................................................................................... 462 Trailing Arm, Rear Axle and Coil Spring Inspection........................................................................................................................................................................... 465 Rear Axle Bush Inspection.................................................................................................................................................................................................... 465 Rear Wheel Hub Components.................................................................................................................................................................................................... 466 Rear Wheel Hub Removal and Installation...................................................................................................................................................................................... 466 Rear Wheel Disc, bolt and Bearing Inspection................................................................................................................................................................................. 467 Spindle Removal and Installation............................................................................................................................................................................................. 468 Spindle Inspection........................................................................................................................................................................................................... 469 Rear Suspension Fasteners Inspection......................................................................................................................................................................................... 469 Specifications................................................................................................................................................................................................................... 469 Tightening Torque Specifications............................................................................................................................................................................................. 469 Special Tools and Equipment...................................................................................................................................................................................................... 469 Special Tool................................................................................................................................................................................................................. 469 Wheels and Tires..................................................................................................................................................................................................................... 470 Precautions...................................................................................................................................................................................................................... 470 Precaution for Emergency Flat Tire Repair Kit................................................................................................................................................................................ 470 General Description.............................................................................................................................................................................................................. 470 Tires Description............................................................................................................................................................................................................ 470 Wheels Description........................................................................................................................................................................................................... 471 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 472 Wear Indicators Description.................................................................................................................................................................................................. 472 Radial Tire Waddle Description............................................................................................................................................................................................... 473 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 474 Balancing Wheels Description................................................................................................................................................................................................. 474 Repair Instructions.............................................................................................................................................................................................................. 475 General Balance Procedures................................................................................................................................................................................................... 475 Tire Rotation................................................................................................................................................................................................................ 475 Wheel Removal and Installation............................................................................................................................................................................................... 476 Tire Mounting and Dismounting................................................................................................................................................................................................ 477 Tire Repair.................................................................................................................................................................................................................. 477 Tire Repair for Emergency Repaired-Tire with Sealant......................................................................................................................................................................... 477 Specifications................................................................................................................................................................................................................... 478 Wheels and Tires Specifications.............................................................................................................................................................................................. 478 Tightening Torque Specifications............................................................................................................................................................................................. 478 Driveline / Axle......................................................................................................................................................................................................................... 479 Precautions.......................................................................................................................................................................................................................... 480 Precautions...................................................................................................................................................................................................................... 480 Precautions for Driveline / Axle............................................................................................................................................................................................. 480 Drive Shaft / Axle................................................................................................................................................................................................................... 481 General Description.............................................................................................................................................................................................................. 481 Front Drive Shaft Construction............................................................................................................................................................................................... 481 Component Location............................................................................................................................................................................................................... 481 Front Drive Shaft Assembly Components Location............................................................................................................................................................................... 481 Diagnostic Information and Procedures............................................................................................................................................................................................ 482 Front Drive Shaft Symptom Diagnosis.......................................................................................................................................................................................... 482 Repair Instructions.............................................................................................................................................................................................................. 483 Front Drive Shaft Components................................................................................................................................................................................................. 483 Front Drive Shaft Assembly On-Vehicle Inspection............................................................................................................................................................................. 484 Front Drive Shaft Assembly Removal and Installation.......................................................................................................................................................................... 484 Front Drive Shaft Disassembly and Reassembly................................................................................................................................................................................. 486 Center Shaft and Center Bearing Support Disassembly and Reassembly........................................................................................................................................................... 494 Specifications................................................................................................................................................................................................................... 495 Tightening Torque Specifications............................................................................................................................................................................................. 495 Special Tools and Equipment...................................................................................................................................................................................................... 495 Recommended Service Material................................................................................................................................................................................................. 495 Special Tool................................................................................................................................................................................................................. 495 Brakes................................................................................................................................................................................................................................... 497 Precautions.......................................................................................................................................................................................................................... 500 Precautions...................................................................................................................................................................................................................... 500 Precautions for Brakes....................................................................................................................................................................................................... 500 Brake Control System and Diagnosis................................................................................................................................................................................................... 501 Precautions...................................................................................................................................................................................................................... 501 Precautions on Brake......................................................................................................................................................................................................... 501 General Description.............................................................................................................................................................................................................. 501 Brakes Construction.......................................................................................................................................................................................................... 501 Brake Pedal Foot Protection System Construction.............................................................................................................................................................................. 502 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 503 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 504 Diagnostic Information and Procedures............................................................................................................................................................................................ 504 Brakes Diagnosis Note........................................................................................................................................................................................................ 504 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 505 Repair Instructions.............................................................................................................................................................................................................. 507 Brake Pedal Components....................................................................................................................................................................................................... 507 Brake Pedal Free Height Inspection........................................................................................................................................................................................... 507 Brake Pedal Play Inspection.................................................................................................................................................................................................. 507 Excessive Pedal Travel Inspection............................................................................................................................................................................................ 508 Brake Fluid Level Inspection................................................................................................................................................................................................. 508 Stop Light Switch Adjustment................................................................................................................................................................................................. 508 Air Bleeding of Brake System................................................................................................................................................................................................. 509 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 510 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 510 Brake Hose and Pipe Inspection............................................................................................................................................................................................... 511 Master Cylinder Components................................................................................................................................................................................................... 511 Master Cylinder Assembly Removal and Installation............................................................................................................................................................................ 512 Master Cylinder Reservoir Removal and Installation........................................................................................................................................................................... 513 Master Cylinder Assembly Disassembly and Assembly............................................................................................................................................................................ 514 Master Cylinder Assembly Inspection.......................................................................................................................................................................................... 515 Brake Booster Components..................................................................................................................................................................................................... 515 Booster Operation Inspection................................................................................................................................................................................................. 516 Brake Booster Removal and Installation....................................................................................................................................................................................... 517 Brake Booster Inspection and Adjustment...................................................................................................................................................................................... 518 Specifications................................................................................................................................................................................................................... 518 Tightening Torque Specifications............................................................................................................................................................................................. 518 Special Tools and Equipment...................................................................................................................................................................................................... 518 Recommended Service Material................................................................................................................................................................................................. 518 Front Brakes......................................................................................................................................................................................................................... 519 Repair Instructions.............................................................................................................................................................................................................. 519 Front Disc Brake Components.................................................................................................................................................................................................. 519 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................... 520 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 520 Front Disc Brake Pad Inspection.............................................................................................................................................................................................. 521 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 521 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 522 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 524 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 524 Front Brake Disc Inspection.................................................................................................................................................................................................. 525 Specifications................................................................................................................................................................................................................... 526 Tightening Torque Specifications............................................................................................................................................................................................. 526 Special Tools and Equipment...................................................................................................................................................................................................... 526 Recommended Service Material................................................................................................................................................................................................. 526 Special Tool................................................................................................................................................................................................................. 526 Rear Brakes.......................................................................................................................................................................................................................... 527 Repair Instructions.............................................................................................................................................................................................................. 527 Rear Disc Brake Components................................................................................................................................................................................................... 527 Rear Disc Brake Pad Removal and Installation................................................................................................................................................................................. 528 Rear Disc Brake Caliper Removal and Installation............................................................................................................................................................................. 529 Rear Disc Brake Pad Inspection............................................................................................................................................................................................... 532 Rear Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................. 532 Rear Disc Brake Caliper Inspection........................................................................................................................................................................................... 534 Rear Flexible Hose Removal and Installation.................................................................................................................................................................................. 534 Rear Brake Disc Removal and Installation..................................................................................................................................................................................... 535 Rear Brake Disc Inspection................................................................................................................................................................................................... 535 Specifications................................................................................................................................................................................................................... 536 Tightening Torque Specifications............................................................................................................................................................................................. 536 Special Tools and Equipment...................................................................................................................................................................................................... 537 Recommended Service Material................................................................................................................................................................................................. 537 Special Tool................................................................................................................................................................................................................. 537 Parking Brake........................................................................................................................................................................................................................ 538 General Description.............................................................................................................................................................................................................. 538 Parking Brake Cable Construction............................................................................................................................................................................................. 538 Repair Instructions.............................................................................................................................................................................................................. 539 Parking Brake Inspection and Adjustment...................................................................................................................................................................................... 539 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 540 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 540 Specifications................................................................................................................................................................................................................... 541 Tightening Torque Specifications............................................................................................................................................................................................. 541 ABS.................................................................................................................................................................................................................................. 542 Precautions...................................................................................................................................................................................................................... 542 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 542 Precautions in On-Vehicle Service............................................................................................................................................................................................ 542 Precautions in Hydraulic Unit Operation Check................................................................................................................................................................................ 542 General Description.............................................................................................................................................................................................................. 543 ABS Description.............................................................................................................................................................................................................. 543 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 543 CAN Communication System Description......................................................................................................................................................................................... 544 Schematic and Routing Diagram.................................................................................................................................................................................................... 545 ABS Schematic................................................................................................................................................................................................................ 545 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 546 Component Location............................................................................................................................................................................................................... 548 ABS Components Location...................................................................................................................................................................................................... 548 Front Wheel Speed Sensor Components Location................................................................................................................................................................................. 548 Rear Wheel Speed Sensor Components Location.................................................................................................................................................................................. 549 Diagnostic Information and Procedures............................................................................................................................................................................................ 549 ABS Check.................................................................................................................................................................................................................... 549 ABS Warning Light Check...................................................................................................................................................................................................... 551 EBD Warning Light (Brake Warning Light) Check................................................................................................................................................................................ 551 DTC Check.................................................................................................................................................................................................................... 552 DTC Table.................................................................................................................................................................................................................... 552 DTC Clearance................................................................................................................................................................................................................ 553 Scan Tool Data............................................................................................................................................................................................................... 553 ABS Warning Light Does Not Come ON at Ignition Switch ON..................................................................................................................................................................... 554 ABS Warning Light Comes ON Steady............................................................................................................................................................................................ 555 EBD Warning Light (Brake Warning Light) Comes ON Steady...................................................................................................................................................................... 556 Serial Data Link Circuit Check............................................................................................................................................................................................... 557 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring.................................................................. 559 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.... 561 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 562 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 563 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 564 DTC C1071: ABS Control Module................................................................................................................................................................................................ 565 DTC U1073: Control Module Communication Bus Off.............................................................................................................................................................................. 566 DTC U1100: Lost Communication with ECM (Reception Error)..................................................................................................................................................................... 568 Repair Instructions.............................................................................................................................................................................................................. 569 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 569 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 570 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 570 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 570 Front / Rear Wheel Speed Sensor On-Vehicle Inspection........................................................................................................................................................................ 572 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 573 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 573 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 574 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 575 Front Wheel Encoder On-Vehicle Inspection.................................................................................................................................................................................... 575 Front wheel Encoder Removal and Installation................................................................................................................................................................................. 575 Rear Wheel Encoder On-Vehicle Inspection..................................................................................................................................................................................... 575 Rear Wheel Encoder Removal and Installation.................................................................................................................................................................................. 575 Specifications................................................................................................................................................................................................................... 576 Tightening Torque Specifications............................................................................................................................................................................................. 576 Special Tools and Equipment...................................................................................................................................................................................................... 576 Special Tool................................................................................................................................................................................................................. 576 Electronic Stability Program......................................................................................................................................................................................................... 577 Precautions...................................................................................................................................................................................................................... 577 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 577 Precautions in On-Vehicle Service............................................................................................................................................................................................ 577 Precautions in Hydraulic Unit Operation Check................................................................................................................................................................................ 577 Precautions in Sensor Calibration............................................................................................................................................................................................ 577 Precautions in Speedometer Test or Other Tests............................................................................................................................................................................... 578 General Description.............................................................................................................................................................................................................. 578 Electronic Stability Program Description..................................................................................................................................................................................... 578 Electronic Stability Program Construction.................................................................................................................................................................................... 579 ESP‚ Hydraulic Unit / Control Module Assembly Description.................................................................................................................................................................... 581 Warning Lamp, Indicator Lamp Description..................................................................................................................................................................................... 582 CAN Communication System Description......................................................................................................................................................................................... 582 CAN Communication System For Electronic Stability Program Description........................................................................................................................................................ 583 Schematic and Routing Diagram.................................................................................................................................................................................................... 584 Electronic Stability Program Schematic....................................................................................................................................................................................... 584 Electronic Stability Program Wiring Circuit Diagram.......................................................................................................................................................................... 585 Component Location............................................................................................................................................................................................................... 587 Electronic Stability Program Component Location.............................................................................................................................................................................. 587 Diagnostic Information and Procedures............................................................................................................................................................................................ 588 Electronic Stability Program System Check.................................................................................................................................................................................... 588 ESP‚ Warning lamp Check...................................................................................................................................................................................................... 590 ABS Warning Lamp Check....................................................................................................................................................................................................... 590 EBD Warning Lamp (Brake Warning Lamp) Check.................................................................................................................................................................................. 591 DTC Check.................................................................................................................................................................................................................... 591 DTC Table.................................................................................................................................................................................................................... 591 DTC Clearance................................................................................................................................................................................................................ 594 Fail-Safe Table.............................................................................................................................................................................................................. 595 Scan Tool Data............................................................................................................................................................................................................... 596 Visual Inspection............................................................................................................................................................................................................ 597 ESP‚ Warning Lamp Does Not Come ON at Ignition Switch ON..................................................................................................................................................................... 597 ESP‚ Warning Lamp Comes ON Steady............................................................................................................................................................................................ 598 ABS Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................... 599 ABS Warning Lamp Comes ON Steady............................................................................................................................................................................................. 600 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady........................................................................................................................................................................ 600 Serial Data Link Circuit Check............................................................................................................................................................................................... 602 DTC C1016: Stop Lamp Switch Circuit Failure.................................................................................................................................................................................. 604 DTC C1017 / C1023: Yaw Rate / G Sensor Assembly Failure...................................................................................................................................................................... 605 DTC C1018: Brake Fluid Level Switch Failure.................................................................................................................................................................................. 606 DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure............................................................................................................................................................... 607 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed Sensor Circuit or Encoder Failure................................................................................................................. 608 DTC C1024: Steering Angle Sensor Circuit Failure............................................................................................................................................................................. 610 DTC C1027: ESP‚ OFF Switch Circuit Failure................................................................................................................................................................................... 610 DTC C1028: Master Cylinder Pressure Sensor Circuit Failure................................................................................................................................................................... 611 DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure................................................................................................................................................................. 612 DTC C1037: Steering Angle Sensor Power Supply Failure........................................................................................................................................................................ 613 DTC C1038: Steering Angle Sensor Detect Rolling Counter Failure from ESP‚ Control Module..................................................................................................................................... 614 DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure..................................................................................................................................................................... 615 DTC C1040: Stability Control System Function Failure......................................................................................................................................................................... 615 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Solenoid Circuit Failure.................................................................................................. 616 DTC C1057: ESP‚ Control Module Power Supply Circuit Failure.................................................................................................................................................................. 617 DTC C1061: Pump Motor and/or Motor Driver Circuit Failure.................................................................................................................................................................... 618 DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure................................................................................................................................................................ 619 DTC 1071: ESP‚ Control Module Internal Defect................................................................................................................................................................................ 620 DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly.............................................................................................................................................................. 621 DTC C1075 / 1076 / 1078: Sensor Calibration Incomplete....................................................................................................................................................................... 622 DTC C1090: Invalid Communication with ECM.................................................................................................................................................................................... 623 DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control Communication with ECM.............................................................................................................................. 624 DTC U1073: Control Module Communication Bus Off.............................................................................................................................................................................. 625 DTC U1100: Lost Communication with ECM (Reception Error)..................................................................................................................................................................... 626 DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error)................................................................................................................................................... 627 DTC U1140: Lost Communication with BCM (Reception Error)..................................................................................................................................................................... 628 Repair Instructions.............................................................................................................................................................................................................. 630 ESP‚ Hydraulic Unit Operation Check.......................................................................................................................................................................................... 630 Sensor Calibration........................................................................................................................................................................................................... 630 ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection.......................................................................................................................................................... 631 ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation....................................................................................................................................................... 632 Front / Rear Wheel Speed Sensor On-Vehicle Inspection........................................................................................................................................................................ 633 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 634 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 635 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 635 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 636 Front Wheel Encoder On-Vehicle Inspection.................................................................................................................................................................................... 637 Front Wheel Encoder Removal and Installation................................................................................................................................................................................. 637 Rear Wheel Encoder On-Vehicle Inspection..................................................................................................................................................................................... 637 Rear Wheel Encoder Removal and Installation.................................................................................................................................................................................. 637 Master Cylinder Pressure Sensor On-Vehicle Inspection........................................................................................................................................................................ 637 Yaw Rate / G Sensor Assembly On-Vehicle Inspection........................................................................................................................................................................... 638 Yaw Rate / G Sensor Assembly Removal and Installation........................................................................................................................................................................ 639 Yaw Rate / G Sensor Inspection............................................................................................................................................................................................... 640 Steering Angle Sensor On-Vehicle Inspection.................................................................................................................................................................................. 640 Steering Angle Sensor Removal and Installation............................................................................................................................................................................... 641 Steering Angle Sensor Inspection............................................................................................................................................................................................. 641 ESP‚ OFF Switch Removal and Installation..................................................................................................................................................................................... 641 ESP‚ OFF Switch Inspection................................................................................................................................................................................................... 641 Specifications................................................................................................................................................................................................................... 642 Tightening Torque Specifications............................................................................................................................................................................................. 642 Special Tools and Equipment...................................................................................................................................................................................................... 642 Special Tool................................................................................................................................................................................................................. 642 Transmission / Transaxle................................................................................................................................................................................................................. 643 Precautions.......................................................................................................................................................................................................................... 646 Precautions...................................................................................................................................................................................................................... 646 Precautions on Transmission / Transaxle...................................................................................................................................................................................... 646 Automatic Transmission/Transaxle..................................................................................................................................................................................................... 647 Precautions...................................................................................................................................................................................................................... 647 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 647 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 647 General Description.............................................................................................................................................................................................................. 649 A/T Description.............................................................................................................................................................................................................. 649 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................................................................................................. 652 Table of Component Operation................................................................................................................................................................................................. 653 Brake Interlock System Construction.......................................................................................................................................................................................... 654 A/T Diagnosis General Description............................................................................................................................................................................................ 654 On-Board Diagnostic System Description....................................................................................................................................................................................... 654 CAN Communication System Description......................................................................................................................................................................................... 655 Schematic and Routing Diagram.................................................................................................................................................................................................... 656 Transmission Control Module (TCM) Wiring Diagram............................................................................................................................................................................. 656 Automatic Gear Shift Table................................................................................................................................................................................................... 658 Component Location............................................................................................................................................................................................................... 659 Electronic Shift Control System Components Location.......................................................................................................................................................................... 659 Diagnostic Information and Procedures............................................................................................................................................................................................ 661 A/T System Check............................................................................................................................................................................................................. 661 Visual Inspection............................................................................................................................................................................................................ 664 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 664 Transmission Warning Light Check............................................................................................................................................................................................. 664 DTC Table.................................................................................................................................................................................................................... 665 DTC Check.................................................................................................................................................................................................................... 666 DTC Clearance................................................................................................................................................................................................................ 666 Fail-Safe Table.............................................................................................................................................................................................................. 667 Scan Tool Data............................................................................................................................................................................................................... 669 A/T Basic Check.............................................................................................................................................................................................................. 672 Road Test.................................................................................................................................................................................................................... 673 Manual Road Test............................................................................................................................................................................................................. 675 Engine Brake Test............................................................................................................................................................................................................ 676 Stall Test................................................................................................................................................................................................................... 676 Time Lag Test................................................................................................................................................................................................................ 677 Line Pressure Test........................................................................................................................................................................................................... 678 “P” Range Test............................................................................................................................................................................................................... 679 A/T Symptom Diagnosis........................................................................................................................................................................................................ 680 No Gear Shift to 4th gear.................................................................................................................................................................................................... 687 No Lock-Up Occurs............................................................................................................................................................................................................ 688 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON.................................................................................................................................... 689 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON.......................................................................................................................................... 689 DTC P0602: Control Module Programming Error.................................................................................................................................................................................. 690 DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL input)....................................................................................................................................................... 690 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................................................................................................. 692 DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low............................................................................................................................................................. 694 DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High............................................................................................................................................................ 695 DTC P0717: Input / Turbine Speed Sensor “A” Circuit Malfunction.............................................................................................................................................................. 697 DTC P0722: Output Speed Sensor Circuit No Signal............................................................................................................................................................................. 698 DTC P0787: Shift / Timing Solenoid Low....................................................................................................................................................................................... 700 DTC P0788: Shift / Timing Solenoid High...................................................................................................................................................................................... 702 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance................................................................................................................................................. 704 DTC P0962: Pressure Control Solenoid “A” Control Circuit Low................................................................................................................................................................. 706 DTC P0963: Pressure Control Solenoid “A” Control Circuit High................................................................................................................................................................ 708 DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low........................................................................................................................... 710 DTC P0974 / P0977: Shift Solenoid “A” / Shift Solenoid “B” Control Circuit High.............................................................................................................................................. 712 DTC P1702: Internal Control Module Memory Check Sum Error.................................................................................................................................................................... 714 DTC P1703: Can Invalid Data - TCM............................................................................................................................................................................................ 714 DTC P1723: Range Select Switch Malfunction................................................................................................................................................................................... 715 DTC P1774: CAN Communication Bus Off......................................................................................................................................................................................... 717 DTC P1777: TCM Lost Communication with ECM (Reception Error)................................................................................................................................................................. 719 DTC P1778: TCM Lost Communication with BCM (Reception Error)................................................................................................................................................................. 720 DTC P1878: Torque Converter Clutch Shudder................................................................................................................................................................................... 721 DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance....................................................................................................................... 722 DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High............................................................................................................................................ 724 DTC P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit Low..................................................................................................................................... 726 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 728 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 732 Brake Interlock System Inspection............................................................................................................................................................................................ 733 Repair Instructions.............................................................................................................................................................................................................. 734 Learning Control Initialization.............................................................................................................................................................................................. 734 A/T Fluid Level Check........................................................................................................................................................................................................ 735 A/T Fluid Change............................................................................................................................................................................................................. 736 Select Lever Components...................................................................................................................................................................................................... 736 Select Lever Assembly Removal and Installation............................................................................................................................................................................... 736 Select Lever Knob Installation............................................................................................................................................................................................... 736 Select Lever Inspection...................................................................................................................................................................................................... 737 “3” Position Switch Inspection............................................................................................................................................................................................... 737 Shift Lock Solenoid Inspection............................................................................................................................................................................................... 737 Shift Lock Solenoid Replacement.............................................................................................................................................................................................. 737 Select Cable Components...................................................................................................................................................................................................... 738 Select Cable Removal and Installation........................................................................................................................................................................................ 738 Select Cable Adjustment...................................................................................................................................................................................................... 739 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 739 Transmission Range Sensor (Shift Switch) Inspection and Adjustment........................................................................................................................................................... 741 Output Shaft Speed Sensor Removal and Installation........................................................................................................................................................................... 742 Output Shaft Speed Sensor Inspection......................................................................................................................................................................................... 742 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 742 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 743 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 743 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 744 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation................................................................................................................................... 744 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection................................................................................................................................................ 745 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...................................................................................................... 747 Pressure Control Solenoid Valve Inspection................................................................................................................................................................................... 747 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 748 A/T Relay Inspection......................................................................................................................................................................................................... 749 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 749 A/T Fluid Cooler Hoses Replacement........................................................................................................................................................................................... 750 Automatic Transaxle Unit Components.......................................................................................................................................................................................... 751 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................... 752 Automatic Transaxle Assembly Components...................................................................................................................................................................................... 754 Automatic Transaxle Unit Disassembly......................................................................................................................................................................................... 756 Oil Pump Assembly Components................................................................................................................................................................................................. 767 Oil Pump Assembly Disassembly and Reassembly................................................................................................................................................................................. 768 Oil Pump Assembly Inspection................................................................................................................................................................................................. 768 Direct Clutch Assembly Components............................................................................................................................................................................................ 770 Direct Clutch Assembly Preliminary Check..................................................................................................................................................................................... 770 Direct Clutch Assembly Disassembly and Reassembly............................................................................................................................................................................ 771 Direct Clutch Assembly Inspection............................................................................................................................................................................................ 773 Forward and Reverse Clutch Assembly Components............................................................................................................................................................................... 774 Forward and Reverse Clutch Assembly Preliminary Check........................................................................................................................................................................ 775 Forward and Reverse Clutch Assembly Disassembly and Reassembly............................................................................................................................................................... 775 Forward and Reverse Clutch Assembly Inspection............................................................................................................................................................................... 779 2nd Brake Piston Assembly Components......................................................................................................................................................................................... 780 2nd Brake Piston Assembly Disassembly and Reassembly......................................................................................................................................................................... 780 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components.................................................................................................................................................... 781 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly.................................................................................................................................... 782 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection.................................................................................................................................................... 783 Countershaft Assembly Components............................................................................................................................................................................................. 784 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 784 Valve Body Assembly Components............................................................................................................................................................................................... 785 Valve Body Assembly Disassembly and Reassembly............................................................................................................................................................................... 786 Differential Assembly Components............................................................................................................................................................................................. 787 Differential Assembly Disassembly and Reassembly............................................................................................................................................................................. 788 Differential Assembly Inspection............................................................................................................................................................................................. 789 Torque Converter Housing Disassembly and Reassembly.......................................................................................................................................................................... 790 Transaxle Case Disassembly and Reassembly.................................................................................................................................................................................... 792 Automatic Transaxle Unit Inspection and Adjustment........................................................................................................................................................................... 793 Automatic Transaxle Unit Assembly............................................................................................................................................................................................ 796 Specifications................................................................................................................................................................................................................... 813 Tightening Torque Specifications............................................................................................................................................................................................. 813 Special Tools and Equipment...................................................................................................................................................................................................... 814 Recommended Service Material................................................................................................................................................................................................. 814 Special Tool................................................................................................................................................................................................................. 814 Manual Transmission/Transaxle........................................................................................................................................................................................................ 817 General Description.............................................................................................................................................................................................................. 817 Manual Transaxle Construction and Servicing.................................................................................................................................................................................. 817 Diagnostic Information and Procedures............................................................................................................................................................................................ 819 Manual Transaxle Symptom Diagnosis........................................................................................................................................................................................... 819 Repair Instructions.............................................................................................................................................................................................................. 819 Manual Transaxle Oil Change.................................................................................................................................................................................................. 819 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 820 Gear Shift Control Lever and Cable Components................................................................................................................................................................................ 821 Gear Shift Control Lever and Cable Removal and Installation.................................................................................................................................................................. 822 Gear Select Control Cable Adjustment......................................................................................................................................................................................... 822 Back Up Light Switch Removal and Installation................................................................................................................................................................................ 823 Back Up Light Switch Inspection.............................................................................................................................................................................................. 823 Manual Transaxle Unit Components............................................................................................................................................................................................. 824 Manual Transaxle Unit Dismounting and Remounting............................................................................................................................................................................. 825 Gear Shift and Select Shaft Assembly Components.............................................................................................................................................................................. 827 Gear Shift and Select Shaft Assembly Removal and Installation................................................................................................................................................................ 827 Gear Shift and Select Shaft Disassembly and Assembly......................................................................................................................................................................... 828 Manual Transaxle Assembly Components......................................................................................................................................................................................... 829 Fifth Gear Disassembly and Assembly.......................................................................................................................................................................................... 830 Manual Transaxle Assembly Disassembly and Reassembly......................................................................................................................................................................... 832 Transaxle Right Case Disassembly and Assembly................................................................................................................................................................................ 839 Transaxle Left Case Disassembly and Assembly................................................................................................................................................................................. 840 Input Shaft and Countershaft Components...................................................................................................................................................................................... 841 Input Shaft Assembly Disassembly and Reassembly.............................................................................................................................................................................. 842 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 844 Synchronizer Parts Inspection................................................................................................................................................................................................ 847 Gear Shift Shaft Components.................................................................................................................................................................................................. 847 5th and Reverse Gear Shift Shafts Disassembly and Assembly................................................................................................................................................................... 848 Gear Shift Shaft and Fork Inspection......................................................................................................................................................................................... 848 Differential Components...................................................................................................................................................................................................... 849 Differential Disassembly and Assembly........................................................................................................................................................................................ 849 Specifications................................................................................................................................................................................................................... 851 Tightening Torque Specifications............................................................................................................................................................................................. 851 Special Tools and Equipment...................................................................................................................................................................................................... 852 Recommended Service Material................................................................................................................................................................................................. 852 Special Tool................................................................................................................................................................................................................. 852 Clutch............................................................................................................................................................................................................................... 855 General Description.............................................................................................................................................................................................................. 855 Clutch Construction.......................................................................................................................................................................................................... 855 Diagnostic Information and Procedures............................................................................................................................................................................................ 856 Clutch System Symptom Diagnosis.............................................................................................................................................................................................. 856 Repair Instructions.............................................................................................................................................................................................................. 856 Clutch Pedal Inspection...................................................................................................................................................................................................... 856 Clutch Fluid Level Inspection................................................................................................................................................................................................ 857 Air Bleeding of Clutch System................................................................................................................................................................................................ 857 Clutch Pedal Position (CPP) Switch Removal and Installation.................................................................................................................................................................. 858 Clutch Pedal Position (CPP) Switch Inspection and Adjustment................................................................................................................................................................. 859 Clutch Fluid Pipe and Hose Components........................................................................................................................................................................................ 859 Clutch Fluid Pipe Removal and Installation................................................................................................................................................................................... 860 Clutch Fluid Pipe Inspection................................................................................................................................................................................................. 860 Clutch Master Cylinder Removal and Installation.............................................................................................................................................................................. 860 Clutch Operating Cylinder Removal and Installation........................................................................................................................................................................... 861 Clutch Operating Cylinder Inspection......................................................................................................................................................................................... 861 Clutch Pedal and Clutch Pedal Bracket Components............................................................................................................................................................................. 861 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................................................................................................ 862 Clutch Cover, Clutch Disc and Flywheel Removal and Installation.............................................................................................................................................................. 862 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................................................................................................ 864 Clutch Release System Removal and Installation............................................................................................................................................................................... 865 Clutch Release System Inspection............................................................................................................................................................................................. 867 Specifications................................................................................................................................................................................................................... 867 Tightening Torque Specifications............................................................................................................................................................................................. 867 Special Tools and Equipment...................................................................................................................................................................................................... 868 Recommended Service Material................................................................................................................................................................................................. 868 Special Tool................................................................................................................................................................................................................. 868 Steering................................................................................................................................................................................................................................. 869 Precautions.......................................................................................................................................................................................................................... 871 Precautions...................................................................................................................................................................................................................... 871 Precautions on Steering...................................................................................................................................................................................................... 871 Steering General Diagnosis........................................................................................................................................................................................................... 872 Precautions...................................................................................................................................................................................................................... 872 Precautions for Steering Diagnosis........................................................................................................................................................................................... 872 Diagnostic Information and Procedures............................................................................................................................................................................................ 873 Steering Symptom Diagnosis................................................................................................................................................................................................... 873 Steering Wheel and Column............................................................................................................................................................................................................ 874 Precautions...................................................................................................................................................................................................................... 874 Service Precautions of Steering Wheel and Column............................................................................................................................................................................. 874 General Description.............................................................................................................................................................................................................. 874 Steering Wheel and Column Construction....................................................................................................................................................................................... 874 Diagnostic Information and Procedures............................................................................................................................................................................................ 875 Checking Steering Column for Accident Damage................................................................................................................................................................................. 875 Repair Instructions.............................................................................................................................................................................................................. 876 Steering Wheel and Column Construction....................................................................................................................................................................................... 876 Steering Wheel Removal and Installation...................................................................................................................................................................................... 877 Contact Coil Cable Assembly Removal and Installation......................................................................................................................................................................... 878 Centering Contact Coil Cable Assembly........................................................................................................................................................................................ 879 Contact Coil Cable Assembly Inspection....................................................................................................................................................................................... 879 Steering Angle Sensor Removal and Installation............................................................................................................................................................................... 879 Steering Angle Sensor Inspection............................................................................................................................................................................................. 879 Steering Column Removal and Installation..................................................................................................................................................................................... 880 Steering Column Inspection................................................................................................................................................................................................... 881 Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)........................................................................................................................................ 882 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................ 882 Steering Lower Shaft Removal and Installation................................................................................................................................................................................ 883 Specifications................................................................................................................................................................................................................... 884 Tightening Torque Specifications............................................................................................................................................................................................. 884 Special Tools and Equipment...................................................................................................................................................................................................... 884 Special Tool................................................................................................................................................................................................................. 884 Power Assisted Steering System....................................................................................................................................................................................................... 885 Precautions...................................................................................................................................................................................................................... 885 Steering System Note......................................................................................................................................................................................................... 885 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 885 General Description.............................................................................................................................................................................................................. 886 P/S System Description....................................................................................................................................................................................................... 886 EPS Diagnosis General Description............................................................................................................................................................................................ 887 On-Board Diagnostic System Description....................................................................................................................................................................................... 887 Schematic and Routing Diagram.................................................................................................................................................................................................... 888 EPS System Wiring Circuit Diagram............................................................................................................................................................................................ 888 Diagnostic Information and Procedures............................................................................................................................................................................................ 889 EPS System Check............................................................................................................................................................................................................. 889 “EPS” Warning Light Check.................................................................................................................................................................................................... 892 DTC Check.................................................................................................................................................................................................................... 892 DTC Clearance................................................................................................................................................................................................................ 893 DTC Table.................................................................................................................................................................................................................... 893 Scan Tool Data............................................................................................................................................................................................................... 895 Visual Inspection............................................................................................................................................................................................................ 896 P/S System Symptom Diagnosis................................................................................................................................................................................................. 896 Serial Data Link Circuit Check............................................................................................................................................................................................... 897 “EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts..................................................................................................................................... 899 “EPS” Warning Light Remains ON Steady after Engine Starts.................................................................................................................................................................... 900 DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation......................................................................................................................................................... 901 DTC C1114: Steering Torque Sensor Reference Power Supply Circuit............................................................................................................................................................. 903 DTC C1117: Steering Torque Sensor Failure Signal Circuit Low................................................................................................................................................................. 905 DTC C1118: Steering Torque Sensor Failure Signal Circuit High................................................................................................................................................................ 906 DTC C1119: Steering Torque Sensor Power Supply Circuit....................................................................................................................................................................... 908 DTC C1121 / C1123 / C1124: VSS Circuit Failure............................................................................................................................................................................... 910 DTC C1122: Engine Speed Signal............................................................................................................................................................................................... 912 DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure................................................................................................................................................................. 914 DTC C1153: P/S Control Module Power Supply Circuit Voltage Low............................................................................................................................................................... 916 DTC C1155: P/S Control Module Failure........................................................................................................................................................................................ 917 P/S Control Module Power Supply and Ground Circuit Check..................................................................................................................................................................... 918 Inspection of P/S Control Module and Its Circuits............................................................................................................................................................................ 919 Steering Wheel Play Check.................................................................................................................................................................................................... 923 Steering Force Check......................................................................................................................................................................................................... 923 Repair Instructions.............................................................................................................................................................................................................. 924 Steering Gear Case Assembly Components....................................................................................................................................................................................... 924 Tie-Rod End Boot On-Vehicle Inspection....................................................................................................................................................................................... 925 Tie-Rod End Removal and Installation......................................................................................................................................................................................... 925 Tie-Rod End Inspection....................................................................................................................................................................................................... 926 Steering Shaft Joint On-Vehicle Inspection................................................................................................................................................................................... 926 Steering Gear Case Assembly Removal and Installation......................................................................................................................................................................... 926 Steering Rack Boot Inspection................................................................................................................................................................................................ 927 Tie-Rod / Rack Boot Removal and Installation................................................................................................................................................................................. 927 Steering Rack Plunger Removal and Installation............................................................................................................................................................................... 929 Steering Rack Plunger Inspection............................................................................................................................................................................................. 929 P/S Control Module Removal and Installation.................................................................................................................................................................................. 930 Torque Sensor and Its Circuit Inspection..................................................................................................................................................................................... 930 P/S Motor and Its Circuit Inspection......................................................................................................................................................................................... 931 Specifications................................................................................................................................................................................................................... 932 Tightening Torque Specifications............................................................................................................................................................................................. 932 Special Tools and Equipment...................................................................................................................................................................................................... 933 Recommended Service Material................................................................................................................................................................................................. 933 Special Tool................................................................................................................................................................................................................. 933 HVAC..................................................................................................................................................................................................................................... 935 Precautions.......................................................................................................................................................................................................................... 938 Precautions...................................................................................................................................................................................................................... 938 Precautions on HVAC.......................................................................................................................................................................................................... 938 Heater and Ventilation............................................................................................................................................................................................................... 939 General Description.............................................................................................................................................................................................................. 939 Heater and Ventilation Construction.......................................................................................................................................................................................... 939 Schematic and Routing Diagram.................................................................................................................................................................................................... 940 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................ 940 Diagnostic Information and Procedures............................................................................................................................................................................................ 941 Heater and Ventilation Symptom Diagnosis..................................................................................................................................................................................... 941 Repair Instructions.............................................................................................................................................................................................................. 942 HVAC Unit Components......................................................................................................................................................................................................... 942 HVAC Unit Removal and Installation........................................................................................................................................................................................... 942 Blower Motor Removal and Installation........................................................................................................................................................................................ 942 Blower Motor Inspection...................................................................................................................................................................................................... 942 Blower Motor Resistor Removal and Installation............................................................................................................................................................................... 943 Blower Motor Resistor Inspection............................................................................................................................................................................................. 943 Blower Motor Relay Inspection................................................................................................................................................................................................ 944 HVAC Control Unit Components................................................................................................................................................................................................. 944 HVAC Control Unit Removal and Installation................................................................................................................................................................................... 945 Blower Speed Selector Inspection............................................................................................................................................................................................. 947 Air Intake Selector Inspection............................................................................................................................................................................................... 947 Air Intake Control Actuator Removal and Installation......................................................................................................................................................................... 947 Air Intake Control Actuator Inspection....................................................................................................................................................................................... 948 Center Ventilation Louver Removal and Installation........................................................................................................................................................................... 948 Side Ventilation Louver Removal and Installation............................................................................................................................................................................. 949 HVAC Air Filter Removal and Installation (If Equipped)....................................................................................................................................................................... 950 HVAC Air Filter Inspection (If Equipped)..................................................................................................................................................................................... 950 Air Conditioning System.............................................................................................................................................................................................................. 951 Manual Type...................................................................................................................................................................................................................... 951 Precautions.................................................................................................................................................................................................................. 951 A/C System Caution....................................................................................................................................................................................................... 951 Precautions on Servicing A/C System...................................................................................................................................................................................... 951 General Description.......................................................................................................................................................................................................... 953 Refrigerant Type Identification.......................................................................................................................................................................................... 953 Sub-Cool A/C System Description.......................................................................................................................................................................................... 954 A/C Operation Description................................................................................................................................................................................................ 954 Schematic and Routing Diagram................................................................................................................................................................................................ 955 Major Components of A/C System........................................................................................................................................................................................... 955 A/C System Wiring Diagram................................................................................................................................................................................................ 956 Diagnostic Information and Procedures........................................................................................................................................................................................ 957 A/C System Symptom Diagnosis............................................................................................................................................................................................. 957 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 959 A/C System Performance Inspection........................................................................................................................................................................................ 960 A/C System Inspection at ECM............................................................................................................................................................................................. 965 Repair Instructions.......................................................................................................................................................................................................... 966 Operation Procedure for Refrigerant Charge............................................................................................................................................................................... 966 Condenser Assembly On-Vehicle Inspection................................................................................................................................................................................. 971 Condenser Assembly Removal and Installation.............................................................................................................................................................................. 971 Receiver/Dryer Removal and Installation.................................................................................................................................................................................. 972 HVAC Unit Components..................................................................................................................................................................................................... 973 HVAC Unit Removal and Installation....................................................................................................................................................................................... 974 Evaporator Inspection.................................................................................................................................................................................................... 974 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation........................................................................................................................................... 975 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection......................................................................................................................................................... 975 Expansion Valve Removal and Installation................................................................................................................................................................................. 976 Expansion Valve Inspection............................................................................................................................................................................................... 976 A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................................................................................................................................... 976 A/C Refrigerant Pressure Sensor Removal and Installation................................................................................................................................................................. 976 A/C Switch Inspection.................................................................................................................................................................................................... 977 Compressor Relay Inspection.............................................................................................................................................................................................. 977 Compressor Drive Belt Inspection and Adjustment.......................................................................................................................................................................... 977 Compressor Drive Belt Removal and Installation........................................................................................................................................................................... 978 Compressor Assembly Removal and Installation............................................................................................................................................................................. 978 Compressor Assembly Components........................................................................................................................................................................................... 979 Magnet Clutch Inspection................................................................................................................................................................................................. 979 Magnet Clutch Removal and Installation................................................................................................................................................................................... 979 Relief Valve Inspection.................................................................................................................................................................................................. 981 Relief Valve Removal and Installation.................................................................................................................................................................................... 982 Specifications............................................................................................................................................................................................................... 982 Tightening Torque Specifications......................................................................................................................................................................................... 982 Special Tools and Equipment.................................................................................................................................................................................................. 983 Recommended Service Material............................................................................................................................................................................................. 983 Special Tool............................................................................................................................................................................................................. 983 Automatic Type................................................................................................................................................................................................................... 984 Precautions.................................................................................................................................................................................................................. 984 A/C System Caution....................................................................................................................................................................................................... 984 Precautions in Diagnosing Trouble........................................................................................................................................................................................ 984 Precautions on Servicing A/C System...................................................................................................................................................................................... 984 General Description.......................................................................................................................................................................................................... 984 Auto A/C System Description.............................................................................................................................................................................................. 984 HVAC Control Module Operation Description................................................................................................................................................................................ 986 Refrigerant Type Identification.......................................................................................................................................................................................... 986 Sub-Cool A/C System Description.......................................................................................................................................................................................... 986 A/C Operation Description................................................................................................................................................................................................ 986 On-Board Diagnostic System Description................................................................................................................................................................................... 987 Schematic and Routing Diagram................................................................................................................................................................................................ 987 Major Components of A/C System........................................................................................................................................................................................... 987 A/C System Wiring Diagram................................................................................................................................................................................................ 988 Diagnostic Information and Procedures........................................................................................................................................................................................ 989 A/C System Symptom Diagnosis............................................................................................................................................................................................. 989 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 992 DTC Check................................................................................................................................................................................................................ 992 DTC Clearance............................................................................................................................................................................................................ 993 DTC Table................................................................................................................................................................................................................ 994 Fail-Safe Table.......................................................................................................................................................................................................... 995 Scan Tool Data........................................................................................................................................................................................................... 996 Air Conditioning System Check............................................................................................................................................................................................ 997 Visual Inspection........................................................................................................................................................................................................ 999 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction.................................................................................................................................................. 999 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction..........................................................................................................................................1000 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction.................................................................................................................................................................1002 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................................................................................................1003 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction....................................................................................................................................1005 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction...................................................................................................................................................1007 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction......................................................................................................................................................1010 DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction..........................................................................................................................................................1012 DTC B1546: A/C Refrigerant Pressure Malfunction..........................................................................................................................................................................1013 DTC B1551: Serial Communication Circuit Malfunction......................................................................................................................................................................1013 DTC B1552: Serial Communication Signal Malfunction.......................................................................................................................................................................1014 DTC B1553: CAN Communication Signal Malfunction..........................................................................................................................................................................1015 DTC B1557: Vehicle Speed Sensor Signal Malfunction.......................................................................................................................................................................1015 DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction..........................................................................................................................................................1016 DTC B1562: Outside Air Temperature Sensor Signal Malfunction.............................................................................................................................................................1016 DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction............................................................................................................................................................1016 Inspection of HVAC Control Module and Its Circuit........................................................................................................................................................................1017 A/C System Performance Inspection........................................................................................................................................................................................1020 A/C System Inspection at ECM.............................................................................................................................................................................................1020 Repair Instructions..........................................................................................................................................................................................................1021 Operation Procedure for Refrigerant Charge...............................................................................................................................................................................1021 HVAC Unit Components.....................................................................................................................................................................................................1022 HVAC Unit Removal and Installation.......................................................................................................................................................................................1023 Temperature Control Actuator Removal and Installation....................................................................................................................................................................1023 Temperature Control Actuator Inspection..................................................................................................................................................................................1023 Air Flow Control Actuator Removal and Installation.......................................................................................................................................................................1024 Air Flow Control Actuator Inspection.....................................................................................................................................................................................1024 Air Intake Control Actuator Removal and Installation.....................................................................................................................................................................1025 Air Intake Control Actuator Inspection...................................................................................................................................................................................1025 Actuator Linkage Inspection..............................................................................................................................................................................................1026 Blower Motor Controller Removal and Installation.........................................................................................................................................................................1026 Blower Motor Controller Inspection.......................................................................................................................................................................................1026 HVAC Control Module Removal and Installation.............................................................................................................................................................................1027 Sunload Sensor Removal and Installation..................................................................................................................................................................................1027 Sunload Sensor Inspection................................................................................................................................................................................................1027 Outside Air Temperature Sensor Removal and Installation..................................................................................................................................................................1027 Outside Air Temperature Sensor Inspection................................................................................................................................................................................1027 Inside Air Temperature Sensor Removal and Installation...................................................................................................................................................................1028 Inside Air Temperature Sensor Inspection.................................................................................................................................................................................1028 Condenser Assembly On-Vehicle Inspection.................................................................................................................................................................................1028 Condenser Assembly Removal and Installation..............................................................................................................................................................................1028 Receiver/Dryer Removal and Installation..................................................................................................................................................................................1028 Evaporator Inspection....................................................................................................................................................................................................1028 Evaporator Temperature Sensor Removal and Installation...................................................................................................................................................................1028 Evaporator Temperature Sensor Inspection.................................................................................................................................................................................1028 Expansion Valve Removal and Installation.................................................................................................................................................................................1028 Expansion Valve Inspection...............................................................................................................................................................................................1028 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...............................................................................................................................................................1028 A/C Refrigerant Pressure Sensor Removal and Installation.................................................................................................................................................................1028 Compressor Relay Inspection..............................................................................................................................................................................................1028 Compressor Drive Belt Inspection and Adjustment..........................................................................................................................................................................1028 Compressor Drive Belt Removal and Installation...........................................................................................................................................................................1029 Compressor Assembly Removal and Installation.............................................................................................................................................................................1029 Compressor Assembly Components...........................................................................................................................................................................................1029 Magnet Clutch Removal and Installation...................................................................................................................................................................................1029 Magnet Clutch Inspection.................................................................................................................................................................................................1029 Relief Valve Inspection..................................................................................................................................................................................................1029 Special Tools and Equipment..................................................................................................................................................................................................1029 Special Tool.............................................................................................................................................................................................................1029 Restraint................................................................................................................................................................................................................................1031 Precautions..........................................................................................................................................................................................................................1033 Precautions......................................................................................................................................................................................................................1033 Precautions on Restraint.....................................................................................................................................................................................................1033 Seat Belts...........................................................................................................................................................................................................................1034 Precautions......................................................................................................................................................................................................................1034 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................1034 General Description..............................................................................................................................................................................................................1034 Seat Belt Construction.......................................................................................................................................................................................................1034 Diagnostic Information and Procedures............................................................................................................................................................................................1035 Repair and Inspection Required after Accident................................................................................................................................................................................1035 Repair Instructions..............................................................................................................................................................................................................1036 Front Seat Belt Components...................................................................................................................................................................................................1036 Front Seat Belt Removal and Installation.....................................................................................................................................................................................1037 Front Seat Belt Inspection...................................................................................................................................................................................................1037 Rear Seat Belt Components....................................................................................................................................................................................................1039 Rear Seat Belt Removal and Installation......................................................................................................................................................................................1040 Rear Seat Belt Inspection....................................................................................................................................................................................................1040 Specifications...................................................................................................................................................................................................................1040 Tightening Torque Specifications.............................................................................................................................................................................................1040 Air Bag System.......................................................................................................................................................................................................................1041 Precautions......................................................................................................................................................................................................................1041 Precautions on Service and Diagnosis of Air Bag System.......................................................................................................................................................................1041 Precautions on Handling and Storage of Air Bag System Components.............................................................................................................................................................1042 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................1045 General Description..............................................................................................................................................................................................................1045 Air Bag System Construction..................................................................................................................................................................................................1045 Air Bag System Input / Output Table..........................................................................................................................................................................................1046 Schematic and Routing Diagram....................................................................................................................................................................................................1047 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................1047 Component Location...............................................................................................................................................................................................................1049 Air Bag System Components, Wiring and Connectors Location....................................................................................................................................................................1049 Diagnostic Information and Procedures............................................................................................................................................................................................1050 Air Bag Diagnostic System Check..............................................................................................................................................................................................1050 Air Bag Diagnostic System Check Flow.........................................................................................................................................................................................1050 DTC Table....................................................................................................................................................................................................................1051 DTC Check....................................................................................................................................................................................................................1052 DTC Clearance................................................................................................................................................................................................................1052 Scan Tool Data...............................................................................................................................................................................................................1053 “AIR BAG” Warning Right Comes ON Steady......................................................................................................................................................................................1053 “AIR BAG” Warning Right Does Not Come ON.....................................................................................................................................................................................1055 “AIR BAG” Warning Right Flashes..............................................................................................................................................................................................1056 DTC B1013: SDM fault.........................................................................................................................................................................................................1057 DTC B1014: “AIR BAG” Warning Right Circuit Failure...........................................................................................................................................................................1057 DTC B1016: Power Source Voltage High.........................................................................................................................................................................................1058 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1060 DTC B1021: Front Air Bag Module Deployed.....................................................................................................................................................................................1062 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed................................................................................................................................................................1062 DTC B1026: Pretensioner Activated............................................................................................................................................................................................1063 DTC B1027: Reusable Number Exceeded..........................................................................................................................................................................................1064 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1064 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1069 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1074 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1079 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1084 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1087 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1090 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1093 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1096 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1098 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1100 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1102 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.........................................................................................................................................1104 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low..........................................................................................................................................1107 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.........................................................................................................................................1110 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit..................................................................................................................................1113 DTC B1071: Forward-Sensor Performance Problem................................................................................................................................................................................1116 DTC B1072: Forward-Sensor Communication Error................................................................................................................................................................................1116 DTC B1073: Forward-Sensor Circuit Short to Ground............................................................................................................................................................................1116 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open.............................................................................................................................................................1118 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem........................................................................................................................................................1120 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error........................................................................................................................................................1120 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground....................................................................................................................................................1120 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open.....................................................................................................................................1121 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID............................................................................................................................................................1123 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High.................................................................................................................................1124 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low..................................................................................................................................1126 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground.................................................................................................................................1128 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit..........................................................................................................................1130 Contact Coil Cable and Its Circuit Check.....................................................................................................................................................................................1133 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1135 Repair and Inspection Required after Accident................................................................................................................................................................................1136 Repair Instructions..............................................................................................................................................................................................................1138 Disabling Air Bag System.....................................................................................................................................................................................................1138 Enabling Air Bag System......................................................................................................................................................................................................1139 SDM Removal and Installation.................................................................................................................................................................................................1140 SDM Inspection...............................................................................................................................................................................................................1141 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1141 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1143 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1143 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1145 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1145 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1147 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1147 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1149 Forward-Sensor Removal and Installation......................................................................................................................................................................................1149 Forward-Sensor Inspection....................................................................................................................................................................................................1150 Side-Sensor Removal and Installation.........................................................................................................................................................................................1150 Side-Sensor Inspection.......................................................................................................................................................................................................1151 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................................................................................................1152 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1153 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1164 Specifications...................................................................................................................................................................................................................1165 Tightening Torque Specifications.............................................................................................................................................................................................1165 Special Tools and Equipment......................................................................................................................................................................................................1165 Use of Special Tools.........................................................................................................................................................................................................1165 Recommended Service Material.................................................................................................................................................................................................1167 Special Tool.................................................................................................................................................................................................................1167 Body, Cab and Accessories................................................................................................................................................................................................................1169 Precautions..........................................................................................................................................................................................................................1173 Precautions......................................................................................................................................................................................................................1173 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1173 Precautions for Body Service.................................................................................................................................................................................................1173 Fastener Caution for Body Service............................................................................................................................................................................................1173 Wiring Systems.......................................................................................................................................................................................................................1174 Precautions......................................................................................................................................................................................................................1174 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1174 General Description..............................................................................................................................................................................................................1174 Abbreviations................................................................................................................................................................................................................1174 Wire / Connector Color Symbols...............................................................................................................................................................................................1174 Symbols and Marks............................................................................................................................................................................................................1175 How to Read Connector Layout Diagram.........................................................................................................................................................................................1177 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1178 How to Read Ground Point.....................................................................................................................................................................................................1180 How to Read Power Supply Diagram.............................................................................................................................................................................................1181 How to Read System Circuit Diagram...........................................................................................................................................................................................1181 Connector Layout Diagram.........................................................................................................................................................................................................1183 Connector Layout Diagram.....................................................................................................................................................................................................1183 Engine Compartment...........................................................................................................................................................................................................1183 Instrument Panel.............................................................................................................................................................................................................1189 Door, Roof...................................................................................................................................................................................................................1193 Floor........................................................................................................................................................................................................................1196 Rear.........................................................................................................................................................................................................................1202 Ground Point.....................................................................................................................................................................................................................1203 Ground (earth) Point.........................................................................................................................................................................................................1203 Power Supply Diagram.............................................................................................................................................................................................................1204 Power Supply Diagram.........................................................................................................................................................................................................1204 Fuses and the Protected Parts................................................................................................................................................................................................1206 Fuses in Main Fuse Box (RHD).................................................................................................................................................................................................1206 Fuses in Main Fuse Box (LHD).................................................................................................................................................................................................1206 Individual Circuit Fuse Box No. 1............................................................................................................................................................................................1207 Individual Circuit Fuse Box No. 2 (In J/B)...................................................................................................................................................................................1208 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1210 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1211 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1213 System Circuit Diagram...........................................................................................................................................................................................................1218 System Circuit Diagram.......................................................................................................................................................................................................1218 A-1 Cranking System Circuit Diagram..........................................................................................................................................................................................1219 A-2 Charging System Circuit Diagram..........................................................................................................................................................................................1220 A-3 Ignition System Circuit Diagram..........................................................................................................................................................................................1221 A-4 Cooling System Circuit Diagram...........................................................................................................................................................................................1222 A-5 Engine and A/C Control System Circuit Diagram............................................................................................................................................................................1223 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1228 A-7 Immobilizer System Circuit Diagram.......................................................................................................................................................................................1230 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1231 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1235 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1236 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1237 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1238 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1240 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1242 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1243 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1244 B-9 Keyless Start System Circuit Diagram.....................................................................................................................................................................................1245 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................................................................................................1246 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................................................................................................1247 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................................................................................................1248 D-1 Headlight System Circuit Diagram.........................................................................................................................................................................................1250 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1252 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1253 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1254 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1255 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1256 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1258 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1259 D-9 Headlight Beam Leveling System Circuit Diagram...........................................................................................................................................................................1260 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1261 E-1 Heater System Circuit Diagram............................................................................................................................................................................................1262 E-2 Auto A/C System Circuit Diagram..........................................................................................................................................................................................1264 F-1 Air-Bag System Circuit Diagram...........................................................................................................................................................................................1266 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1268 F-3 Electronic Stability Program System Circuit Diagram......................................................................................................................................................................1270 F-4 Power Steering System Circuit Diagram....................................................................................................................................................................................1272 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1274 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1275 List of Connector................................................................................................................................................................................................................1276 List of Connectors...........................................................................................................................................................................................................1276 C Connector..................................................................................................................................................................................................................1276 D Connector (M16A engine)....................................................................................................................................................................................................1277 E Connector..................................................................................................................................................................................................................1277 G Connector..................................................................................................................................................................................................................1279 J Connector..................................................................................................................................................................................................................1281 K Connector..................................................................................................................................................................................................................1282 L Connector..................................................................................................................................................................................................................1282 M Connector (SPORT model)....................................................................................................................................................................................................1284 O Connector..................................................................................................................................................................................................................1284 R Connector..................................................................................................................................................................................................................1284 Lighting Systems.....................................................................................................................................................................................................................1285 Component Location...............................................................................................................................................................................................................1285 Lighting System Components Location..........................................................................................................................................................................................1285 Interior Light System Location...............................................................................................................................................................................................1286 Diagnostic Information and Procedures............................................................................................................................................................................................1286 Headlight Symptom Diagnosis..................................................................................................................................................................................................1286 Headlight Leveling System Symptom Diagnosis (If Equipped)....................................................................................................................................................................1286 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1287 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1287 Back-Up Light Symptom Diagnosis..............................................................................................................................................................................................1288 Brake Light Symptom Diagnosis................................................................................................................................................................................................1288 Front Fog Light Symptom Diagnosis (If Equipped)..............................................................................................................................................................................1288 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1289 Repair Instructions..............................................................................................................................................................................................................1289 Headlight Housing Removal and Installation...................................................................................................................................................................................1289 Headlight Bulb Replacement...................................................................................................................................................................................................1290 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1290 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1292 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1292 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1292 Hazard Warning Switch Inspection.............................................................................................................................................................................................1293 Brake Light Switch Inspection................................................................................................................................................................................................1293 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1293 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1293 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1293 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1294 License Light Removal and Installation.......................................................................................................................................................................................1294 Front Fog Light Removal and Installation (If Equipped).......................................................................................................................................................................1295 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1295 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1295 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1295 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1296 Headlight Leveling Switch Inspection (If Equipped)...........................................................................................................................................................................1297 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................................................................................................1297 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1298 Precautions......................................................................................................................................................................................................................1298 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................................................................................................1298 General Description..............................................................................................................................................................................................................1298 CAN Communication System Description.........................................................................................................................................................................................1298 Auto Volume Control System Description (If Equipped).........................................................................................................................................................................1300 Schematic and Routing Diagram....................................................................................................................................................................................................1301 Combination Meter Circuit Diagram............................................................................................................................................................................................1301 Component Location...............................................................................................................................................................................................................1303 Audio System Component Location..............................................................................................................................................................................................1303 Diagnostic Information and Procedures............................................................................................................................................................................................1303 Speedometer and VSS Symptom Diagnosis........................................................................................................................................................................................1303 Tachometer Symptom Diagnosis.................................................................................................................................................................................................1303 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1304 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1304 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1304 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1305 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1305 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1305 A/T Shift Position Indicator Symptom Diagnosis (A/T Model)...................................................................................................................................................................1306 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1306 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1306 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1307 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1307 Horn Symptom Diagnosis.......................................................................................................................................................................................................1307 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1308 Clock Symptom Diagnosis (If Equipped)........................................................................................................................................................................................1309 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1309 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1310 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1311 Repair Instructions..............................................................................................................................................................................................................1311 Ignition Switch Removal and Installation.....................................................................................................................................................................................1311 Ignition Switch Inspection...................................................................................................................................................................................................1311 Combination Meter Removal and Installation...................................................................................................................................................................................1312 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1312 Fuel Level Sensor Inspection.................................................................................................................................................................................................1312 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1312 Oil Pressure Switch Inspection...............................................................................................................................................................................................1313 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1313 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1313 Parking Brake Switch Inspection..............................................................................................................................................................................................1313 Door Switch (Front / Rear Door) Inspection...................................................................................................................................................................................1314 Rear End Door Switch Inspection..............................................................................................................................................................................................1314 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1314 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1314 Instrument Panel Removal and Installation....................................................................................................................................................................................1315 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1316 Audio Unit Removal and Installation..........................................................................................................................................................................................1316 Front Speaker Removal and Installation.......................................................................................................................................................................................1316 Rear Speaker Removal and Installation........................................................................................................................................................................................1317 Horn Removal and Installation................................................................................................................................................................................................1317 Horn Inspection..............................................................................................................................................................................................................1317 Horn Relay Inspection........................................................................................................................................................................................................1317 Antenna Amplifier Removal and Installation...................................................................................................................................................................................1318 Remote Audio Control Switch Removal and Installation (If Equipped)...........................................................................................................................................................1318 Remote Audio Control Switch Inspection (If Equipped).........................................................................................................................................................................1319 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...............................................................................................................................................................1319 Specifications...................................................................................................................................................................................................................1319 Tightening Torque Specifications.............................................................................................................................................................................................1319 Wipers / Washers.....................................................................................................................................................................................................................1320 Diagnostic Information and Procedures............................................................................................................................................................................................1320 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1320 Rear Wiper and Washer Symptom Diagnosis......................................................................................................................................................................................1320 Repair Instructions..............................................................................................................................................................................................................1321 Wipers and Washers Components................................................................................................................................................................................................1321 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1322 Washer Pump Inspection.......................................................................................................................................................................................................1322 Windshield Wiper Removal and Installation....................................................................................................................................................................................1323 Windshield Wiper Motor Inspection............................................................................................................................................................................................1324 Rear Wiper Removal and Installation..........................................................................................................................................................................................1325 Rear Wiper Motor Inspection..................................................................................................................................................................................................1326 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1326 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1327 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1328 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1328 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1329 Rear Wiper Relay Inspection..................................................................................................................................................................................................1329 Specifications...................................................................................................................................................................................................................1329 Tightening Torque Specifications.............................................................................................................................................................................................1329 Glass / Windows / Mirrors............................................................................................................................................................................................................1330 General Description..............................................................................................................................................................................................................1330 Rear End Door Window Defogger System Description.............................................................................................................................................................................1330 Windshield Construction......................................................................................................................................................................................................1330 Diagnostic Information and Procedures............................................................................................................................................................................................1331 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1331 Power Window Control System Symptom Diagnosis................................................................................................................................................................................1331 Power Door Mirror Control System Symptom Diagnosis...........................................................................................................................................................................1332 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1332 Repair Instructions..............................................................................................................................................................................................................1333 Windshield Removal and Installation..........................................................................................................................................................................................1333 Front Door Window Components.................................................................................................................................................................................................1337 Front Door Glass Removal and Installation....................................................................................................................................................................................1337 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1338 Front Door Window Regulator Inspection.......................................................................................................................................................................................1339 Rear Door Window Components..................................................................................................................................................................................................1339 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1340 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1341 Rear Door Window Regulator Inspection........................................................................................................................................................................................1341 Rear End Door Window Components..............................................................................................................................................................................................1342 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1342 Rear End Door Window Defogger Switch Inspection..............................................................................................................................................................................1343 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1343 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1344 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1344 Power Window Main Switch Inspection..........................................................................................................................................................................................1345 Power Window Sub Switch Inspection...........................................................................................................................................................................................1346 Door Mirror Components.......................................................................................................................................................................................................1347 Door Mirror Removal and Installation.........................................................................................................................................................................................1347 Power Door Mirror Switch Inspection..........................................................................................................................................................................................1347 Power Door Mirror Actuator Inspection........................................................................................................................................................................................1348 Door Mirror Heater Switch Inspection (If Equipped)...........................................................................................................................................................................1348 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1348 Special Tools and Equipment......................................................................................................................................................................................................1348 Recommended Service Material.................................................................................................................................................................................................1348 Security and Locks...................................................................................................................................................................................................................1349 General Description..............................................................................................................................................................................................................1349 Key Coding Construction......................................................................................................................................................................................................1349 Rear End Door Opener System Description......................................................................................................................................................................................1349 Component Location...............................................................................................................................................................................................................1350 Power Door Lock and Keyless Entry System Component Location..................................................................................................................................................................1350 Diagnostic Information and Procedures............................................................................................................................................................................................1351 Power Door Lock System Symptom Diagnosis.....................................................................................................................................................................................1351 Power Door Lock System Operation Inspection..................................................................................................................................................................................1351 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1352 Keyless Entry System Operation Inspection....................................................................................................................................................................................1353 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1353 Rear End Door Opener System Symptom Diagnosis................................................................................................................................................................................1353 Rear End Door Opener System Operation Inspection.............................................................................................................................................................................1353 Repair Instructions..............................................................................................................................................................................................................1354 Front Door Lock Assembly Components..........................................................................................................................................................................................1354 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1354 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1356 Power Door Lock Switch Inspection............................................................................................................................................................................................1356 Door Key Cylinder Switch Inspection..........................................................................................................................................................................................1356 Power Door Lock Actuator Inspection..........................................................................................................................................................................................1357 Rear Door Lock Assembly Components...........................................................................................................................................................................................1358 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1358 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1358 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1359 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1359 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1360 Rear End Door Opener Switch Inspection.......................................................................................................................................................................................1360 Replacement of Transmitter Battery...........................................................................................................................................................................................1361 Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System).................................................................................................................................1361 Keyless Entry Answer Back Function Change- over Procedure (If Equipped)......................................................................................................................................................1362 Keyless Entry Receiver Removal and Installation..............................................................................................................................................................................1362 Keyless Entry Receiver and Its Circuit Inspection............................................................................................................................................................................1363 Specifications...................................................................................................................................................................................................................1364 Tightening Torque Specifications.............................................................................................................................................................................................1364 Special Tools and Equipment......................................................................................................................................................................................................1364 Recommended Service Material.................................................................................................................................................................................................1364 Seats................................................................................................................................................................................................................................1365 Repair Instructions..............................................................................................................................................................................................................1365 Front Seat Components........................................................................................................................................................................................................1365 Front Seat Removal and Installation..........................................................................................................................................................................................1366 Rear Seat Components.........................................................................................................................................................................................................1367 Rear Seat Removal and Installation...........................................................................................................................................................................................1368 Specifications...................................................................................................................................................................................................................1368 Tightening Torque Specifications.............................................................................................................................................................................................1368 Special Tools and Equipment......................................................................................................................................................................................................1368 Recommended Service Material.................................................................................................................................................................................................1368 Interior Trim........................................................................................................................................................................................................................1369 Repair Instructions..............................................................................................................................................................................................................1369 Floor Carpet Removal and Installation........................................................................................................................................................................................1369 Head Lining Removal and Installation.........................................................................................................................................................................................1369 Console Box Components.......................................................................................................................................................................................................1370 Specifications...................................................................................................................................................................................................................1371 Tightening Torque Specifications.............................................................................................................................................................................................1371 Hood / Fenders / Doors...............................................................................................................................................................................................................1372 Repair Instructions..............................................................................................................................................................................................................1372 Hood Removal and Installation................................................................................................................................................................................................1372 Hood Inspection and Adjustment...............................................................................................................................................................................................1372 Front Fender Components......................................................................................................................................................................................................1373 Front Fender Removal and Installation........................................................................................................................................................................................1373 Front Door Assembly Components...............................................................................................................................................................................................1374 Front Door Assembly Removal and Installation.................................................................................................................................................................................1374 Rear Door Assembly Components................................................................................................................................................................................................1376 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1376 Rear End Door Assembly Components............................................................................................................................................................................................1377 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1377 Specifications...................................................................................................................................................................................................................1379 Tightening Torque Specifications.............................................................................................................................................................................................1379 Special Tools and Equipment......................................................................................................................................................................................................1379 Recommended Service Material.................................................................................................................................................................................................1379 Body Structure.......................................................................................................................................................................................................................1380 Repair Instructions..............................................................................................................................................................................................................1380 Front Bumper and Rear Bumper Components......................................................................................................................................................................................1380 Cowl Top Components..........................................................................................................................................................................................................1381 Specifications...................................................................................................................................................................................................................1382 Body Dimensions..............................................................................................................................................................................................................1382 Panel Clearance..............................................................................................................................................................................................................1389 Paint / Coatings.....................................................................................................................................................................................................................1390 General Description..............................................................................................................................................................................................................1390 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1390 Plastic Parts Finishing......................................................................................................................................................................................................1391 Component Location...............................................................................................................................................................................................................1392 Sealant Application Areas....................................................................................................................................................................................................1392 Under Coating Application Areas..............................................................................................................................................................................................1397 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1399 Exterior Trim........................................................................................................................................................................................................................1400 Repair Instructions..............................................................................................................................................................................................................1400 Roof Molding Components......................................................................................................................................................................................................1400 Splash Guard (If Equipped) Components........................................................................................................................................................................................1401 Control Systems..........................................................................................................................................................................................................................1403 Precautions..........................................................................................................................................................................................................................1405 Precautions......................................................................................................................................................................................................................1405 Precautions for Control Systems..............................................................................................................................................................................................1405 Body Electrical Control System.......................................................................................................................................................................................................1406 Precautions......................................................................................................................................................................................................................1406 Precautions in Diagnosing Trouble............................................................................................................................................................................................1406 General Description..............................................................................................................................................................................................................1406 BCM General Description......................................................................................................................................................................................................1406 CAN Communication System Description.........................................................................................................................................................................................1407 Theft Deterrent Light........................................................................................................................................................................................................1408 Security Alarm Description (If Equipped).....................................................................................................................................................................................1408 Schematic and Routing Diagram....................................................................................................................................................................................................1409 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1409 Connector Layout Diagram of BCM and Junction Block Assembly..................................................................................................................................................................1412 Component Location...............................................................................................................................................................................................................1413 BCM and Related System Component Location....................................................................................................................................................................................1413 Diagnostic Information and Procedures............................................................................................................................................................................................1414 BCM Self-Diagnosis Function..................................................................................................................................................................................................1414 Body Electrical Control System Check.........................................................................................................................................................................................1415 Scan Tool Data...............................................................................................................................................................................................................1417 DTC Table....................................................................................................................................................................................................................1419 DTC Check....................................................................................................................................................................................................................1419 DTC Clearance................................................................................................................................................................................................................1420 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1421 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1422 DTC B1141 / DTC B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction..............................................................................................................1423 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1424 DTC B1157 (No. 1157): Air Bag Deployment Signal Input........................................................................................................................................................................1425 DTC B1170 (No. 1170): EEPROM Access Error....................................................................................................................................................................................1426 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module..................................................................................................................................1426 DTC U1073 (No. 1073): Control Module Communication Bus Off...................................................................................................................................................................1429 DTC U1100 (No. 1100): Lost Communication with ECM............................................................................................................................................................................1430 DTC U1101 (No. 1101): Lost Communication with TCM............................................................................................................................................................................1432 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1434 Inspection of BCM and its Circuits...........................................................................................................................................................................................1436 Repair Instructions..............................................................................................................................................................................................................1444 BCM (Included in Junction Block Assembly) Removal and Installation...........................................................................................................................................................1444 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1444 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1444 Security Alarm Mode Selection Procedure (If Equipped)........................................................................................................................................................................1444 Special Tools and Equipment......................................................................................................................................................................................................1445 Special Tool.................................................................................................................................................................................................................1445 Immobilizer Control System...........................................................................................................................................................................................................1446 Precautions......................................................................................................................................................................................................................1446 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1446 Precaution in Replacing ECM..................................................................................................................................................................................................1446 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1446 General Description..............................................................................................................................................................................................................1447 Immobilizer Control System Introduction......................................................................................................................................................................................1447 Immobilizer Control System Components Location...............................................................................................................................................................................1448 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................................................................................................1448 Schematic and Routing Diagram....................................................................................................................................................................................................1449 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1449 Diagnostic Information and Procedures............................................................................................................................................................................................1450 Immobilizer Control System Check.............................................................................................................................................................................................1450 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1450 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1451 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1451 Scan Tool Data...............................................................................................................................................................................................................1452 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1452 Immobilizer Indicator Lamp Remains ON after Engine Starts....................................................................................................................................................................1453 DTC P1614: Transponder Response Error........................................................................................................................................................................................1454 DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only).....................................................................................................................................1454 DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only).................................................................................................................................1455 DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)......................................................................................1456 DTC P1621: Immobilizer Communication Line Error..............................................................................................................................................................................1457 DTC P1622: EEPROM Reading / Writing Error....................................................................................................................................................................................1458 DTC P1623: Unregistered Transponder..........................................................................................................................................................................................1458 DTC P1625: Immobilizer Antenna Error.........................................................................................................................................................................................1459 DTC P1636: Immobilizer Information Registration Failure......................................................................................................................................................................1459 DTC P1638: Immobilizer Information Mismatched................................................................................................................................................................................1460 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1461 Repair Instructions..............................................................................................................................................................................................................1463 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1463 Registration of the Ignition Key.............................................................................................................................................................................................1463 Procedure after ECM Replacement..............................................................................................................................................................................................1463 Special Tools and Equipment......................................................................................................................................................................................................1464 Special Tool.................................................................................................................................................................................................................1464 Keyless Start System.................................................................................................................................................................................................................1465 General Description..............................................................................................................................................................................................................1465 Keyless Start System Description.............................................................................................................................................................................................1465 Parts and Functions..........................................................................................................................................................................................................1466 Keyless Engine Start Function................................................................................................................................................................................................1467 Door Lock Function of Keyless Start System...................................................................................................................................................................................1468 Operation Area of Remote Controller..........................................................................................................................................................................................1469 Alarm Function...............................................................................................................................................................................................................1470 CAN Communication System Description.........................................................................................................................................................................................1470 Schematic and Routing Diagram....................................................................................................................................................................................................1471 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1471 Diagnostic Information and Procedures............................................................................................................................................................................................1472 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1472 Self-Diagnosis Function......................................................................................................................................................................................................1472 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1472 Keyless Start System Check...................................................................................................................................................................................................1472 Customer Questionnaire (Example).............................................................................................................................................................................................1473 Key Indicator Lamp Check.....................................................................................................................................................................................................1474 DTC Check....................................................................................................................................................................................................................1474 DTC Table....................................................................................................................................................................................................................1475 DTC Clearance................................................................................................................................................................................................................1476 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1476 Keyless Start System Operation Inspection....................................................................................................................................................................................1477 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1478 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1478 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1482 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.).....................................................................................................................1484 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1486 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1487 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1488 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)..........................................................................................................1488 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1489 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1491 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1492 Repair Instructions..............................................................................................................................................................................................................1494 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1494 Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection..............................................................................................................................................1495 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1495 Steering Lock Unit Inspection................................................................................................................................................................................................1495 Front Door Lock Switch Inspection............................................................................................................................................................................................1495 Keyless Start Control Module Removal and Installation........................................................................................................................................................................1496 Remote Controller Inspection.................................................................................................................................................................................................1496 Replacement of Remote Controller Battery.....................................................................................................................................................................................1496 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1497 COPYRIGHT................................................................................................................................................................................................................................1499 BOOKCOVER_VOL1...........................................................................................................................................................................................................................1500 BOOKCOVER_VOL2...........................................................................................................................................................................................................................1501
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