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SUZUKI SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 561
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
IMPORTANT....................................................................................................... 1 WARNING/CAUTION/NOTE........................................................................................ 1 Foreword........................................................................................................ 2 TABLE OF CONTENTS............................................................................................... 4 SECTION 0A...................................................................................................... 6 CONTENTS.................................................................................................... 6 Precautions................................................................................................. 7 Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System......................... 7 Diagnosis........................................................................................... 7 Servicing and handling.............................................................................. 8 General Precautions..................................................................................... 11 Identification Information.................................................................................. 14 Vehicle Identification Number........................................................................... 14 Engine Identification Number............................................................................ 14 Warning, Caution and Information Labels..................................................................... 15 Abbreviations May Be Used In This Manual.................................................................... 16 Abbreviations........................................................................................... 16 Fasteners Information....................................................................................... 19 Metric Fasteners........................................................................................ 19 SECTION 0B...................................................................................................... 20 CONTENTS.................................................................................................... 20 Maintenance Schedule........................................................................................ 21 Maintenance Schedule Under Normal Driving Conditions.................................................... 21 Maintenance Recommended Under Severe Driving Conditions................................................. 22 Maintenance Service......................................................................................... 23 Engine.................................................................................................. 23 Drive belt.......................................................................................... 23 Camshaft timing belt and tensioner.................................................................. 23 Engine oil and filter............................................................................... 24 Engine coolant...................................................................................... 25 Exhaust system...................................................................................... 26 Fuel System............................................................................................. 26 Air cleaner filter.................................................................................. 26 Fuel lines and connections.......................................................................... 27 Fuel filter......................................................................................... 27 Water Draining of Fuel Filter........................................................................... 27 Fuel tank........................................................................................... 27 Chassis and Body........................................................................................ 28 Clutch.............................................................................................. 28 Brake discs and pads................................................................................ 28 Manual transmission oil............................................................................. 29 Transfer and differential oil....................................................................... 29 Power steering (P/S) system (if equipped)........................................................... 30 Recommended Fluids and Lubricants........................................................................... 30 SECTION 1A...................................................................................................... 32 CONTENTS.................................................................................................... 32 General Description......................................................................................... 33 Additional Heater Assembly.............................................................................. 34 Diagnosis................................................................................................... 35 Diagnosis Table......................................................................................... 35 Wiring Circuit.......................................................................................... 36 On Vehicle Service.......................................................................................... 37 Heater Unit/Boost Ventilation........................................................................... 37 Additional Heater Assembly.............................................................................. 38 Additional Heater Relays................................................................................ 40 SECTION 1B...................................................................................................... 42 CONTENTS.................................................................................................... 42 General Description......................................................................................... 44 Major Components and Location........................................................................... 44 Diagnosis................................................................................................... 45 General Diagnosis Table................................................................................. 45 Compressor Drive Belt................................................................................... 47 Electronical Diagnosis...................................................................................... 48 Wiring Diagram.......................................................................................... 48 On-Vehicle Service.......................................................................................... 50 Service Precaution...................................................................................... 50 Refrigerant line.................................................................................... 50 Condenser Assembly...................................................................................... 51 Receiver/Dryer.......................................................................................... 52 Condenser Cooling Fan Assembly.......................................................................... 52 Cooling Unit (Evaporator)............................................................................... 53 A/C Evaporator Temperature Sensor....................................................................... 55 Refrigerant Pressure Sensor............................................................................. 57 Condenser Cooling Fan Motor Relay....................................................................... 58 Compressor Relay and A/C Relay.......................................................................... 58 Compressor.............................................................................................. 58 Magnet Clutch........................................................................................... 60 Lip Seal................................................................................................ 64 Relief Valve............................................................................................ 66 Tightening Torque Specification............................................................................. 67 Required Service Materials.................................................................................. 67 Special Tools............................................................................................... 67 SECTION 3B1..................................................................................................... 68 CONTENTS.................................................................................................... 68 General Description......................................................................................... 69 Diagnosis................................................................................................... 70 Diagnosis Table......................................................................................... 70 Power Steering Belt Check............................................................................... 72 Power Steering Fluid Level Check........................................................................ 72 Power Steering Fluid Leakage Check...................................................................... 73 Hydraulic Pressure In P/S Circuit Check................................................................. 73 On-Vehicle Service.......................................................................................... 75 Power Steering System Components........................................................................ 75 Power Steering Belt..................................................................................... 76 Power Steering (P/S) Pump............................................................................... 76 Tightening Torque Specifications............................................................................ 77 Required Service Materials.................................................................................. 77 Special Tools............................................................................................... 77 SECTION 3C...................................................................................................... 78 CONTENTS.................................................................................................... 78 Checking Steering Column for Accident Damage................................................................ 79 SECTION 3D...................................................................................................... 82 CONTENTS.................................................................................................... 82 General Description......................................................................................... 83 4WD Control System...................................................................................... 83 Diagnosis................................................................................................... 88 Diagnosis Table......................................................................................... 88 4WD Controller and its Circuit Check.................................................................... 90 4WD Control System Check................................................................................ 91 On-Vehicle Service.......................................................................................... 94 Stabilizer Bar / Bushings............................................................................... 94 Leading Arm / Bushing................................................................................... 95 Special Tool................................................................................................ 97 SECTION 3E......................................................................................................100 CONTENTS....................................................................................................100 General Description.........................................................................................101 On-Vehicle Service..........................................................................................102 Lateral Rod.............................................................................................102 Rear Axle Housing.......................................................................................103 SECTION 5.......................................................................................................108 CONTENTS....................................................................................................108 General Description.........................................................................................110 Diagnosis...................................................................................................111 Stop Light Switch Adjustment............................................................................111 On-Vehicle Service..........................................................................................111 Air Bleeding of Brake System............................................................................111 Front Disc Brake........................................................................................114 Brake pad...........................................................................................115 Caliper assembly....................................................................................117 Brake disc..........................................................................................121 Master Cylinder.........................................................................................124 Master cylinder reservoir...........................................................................124 Master cylinder assembly............................................................................126 Brake Hose / Pipe.......................................................................................128 Front brake hose / pipe.............................................................................128 Rear brake hose / pipe..............................................................................129 Tightening Torque Specifications............................................................................131 Required Service Material...................................................................................131 Special Tool................................................................................................132 SECTION 6-2.....................................................................................................134 CONTENTS....................................................................................................134 General Information.........................................................................................136 Statement of Cleanliness and Care.......................................................................136 General Information on Engine Service...................................................................136 Precaution on fuel system service...................................................................137 Fuel pressure relief confirmation procedure.........................................................137 Fuel leakage check procedure........................................................................137 Engine Diagnosis............................................................................................138 General Description.....................................................................................138 On-Board Diagnostic System..............................................................................138 Precaution in Diagnosing Trouble........................................................................140 Engine Diagnostic Flow Table............................................................................142 Diagnostic step details.............................................................................144 Diagnostic Trouble Code (DTC) Check.....................................................................145 Diagnostic Trouble Code (DTC) Clearance.................................................................145 Diagnostic Trouble Code (DTC) Table.....................................................................146 Indicator lamp operation table..........................................................................148 Visual Inspection.......................................................................................151 Engine Basic Check......................................................................................152 Fault Finding – Fault Interpretation....................................................................153 DTC P0070 External air temperature sensor circuit malfunction.......................................153 DTC P0087 Fuel rail/system pressure too low.........................................................154 DTC P0089 Fuel pressure regulator performance problem...............................................155 DTC P0110 Intake air temperature circuit malfunction................................................156 DTC P0115 Engine coolant temperature circuit malfunction............................................157 DTC P0180 Fuel temperature sensor circuit malfunction...............................................158 DTC P0190 Fuel pressure sensor circuit malfunction..................................................159 DTC P0200 Injector circuit..........................................................................160 DTC P0201 Injector circuit malfunction – cylinder 1.................................................162 DTC P0202 Injector circuit malfunction – cylinder 2.................................................163 DTC P0203 Injector circuit malfunction – cylinder 3.................................................164 DTC P0204 Injector circuit malfunction – cylinder 4.................................................165 DTC P0225 Pedal position sensor 1 circuit...........................................................166 DTC P0231 Fuel pump secondary circuit low...........................................................168 DTC P0235 Turbo pressure sensor circuit malfunction.................................................169 DTC P0301 Cylinder 1 misfire detected...............................................................171 DTC P0302 Cylinder 2 misfire detected...............................................................172 DTC P0303 Cylinder 3 misfire detected...............................................................173 DTC P0304 Cylinder 4 misfire detected...............................................................174 DTC P0325 Knock sensor circuit malfunction..........................................................175 DTC P0335 Crankshaft position sensor circuit malfunction............................................176 DTC P0340 Camshaft position sensor circuit malfunction..............................................177 DTC P0380 Glow plug/heater circuit malfunction......................................................178 DTC P0670 Glow plug module control circuit..........................................................178 DTC P0382 Glow plug/heater circuit B malfunction....................................................179 DTC P0400 Exhaust gas recirculation flow malfunction................................................180 DTC P2413 Exhaust gas recirculation system performance..............................................180 DTC P0402 Exhaust gas recirculation flow excessive detected.........................................181 DTC P0403 Exhaust gas recirculation control circuit.................................................181 DTC P0409 Exhaust gas recirculation sensor circuit..................................................182 DTC P0487 Exhaust gas recirculation throttle position control circuit...............................182 DTC P0480 Radiator cooling fan low speed control system malfunction.................................183 DTC P0481 Radiator cooling fan high speed control system malfunction................................184 DTC P0500 Vehicle speed sensor circuit malfunction..................................................185 DTC P0513 Incorrect immobilizer key.................................................................186 DTC P0530 A/C refrigerant pressure sensor circuit malfunction.......................................187 DTC P0560 System voltage............................................................................188 DTC P0604 Control module internal fail..............................................................189 DTC P0605 Control module program error..............................................................190 DTC P0606 Control module program error..............................................................190 DTC P0608 Sensor supply circuit 1 fail..............................................................192 DTC P0609 Sensor supply circuit 2 fail..............................................................193 DTC P0651 Sensor reference voltage circuit/open.....................................................193 DTC P0645 A/C compressor relay control circuit malfunction..........................................194 DTC P0685 Main relay control circuit malfunction....................................................195 DTC P103D A/C signal circuit malfunction............................................................196 DTC P1641 Additional heater relay circuit 1.........................................................197 DTC P1643 Additional heater relay circuit 2.........................................................198 DTC P2120 Pedal position sensor 2 circuit...........................................................199 DTC P2226 Barometric pressure circuit malfunction...................................................201 Fault Finding – Customer Complaints.....................................................................202 Table 1 No dialogue with the ECM....................................................................203 Table 2 The engine does not start...................................................................204 Table 3 The engine starts with difficulty or starts then stalls.....................................205 Table 4 Starting difficult with warm engine.........................................................206 Table 5 Rough idle speed (pumping)..................................................................207 Table 6 Idle speed too high/too low.................................................................208 Table 7 Unexpected acceleration/deceleration and engine stalling....................................209 Table 8 Response fault..............................................................................210 Table 9 Engine stop/stalling........................................................................211 Table 10 Engine jerking.............................................................................212 Table 11 Lack of power..............................................................................213 Table 12 Too much power.............................................................................214 Table 13 Excessive consumption......................................................................215 Table 14 Overspeed when lifting off accelerator or changing gear....................................216 Table 15 Engine dies on pulling away................................................................217 Table 16 The engine does not stop...................................................................218 Table 17 Clanking engine, noisy engine..............................................................219 Table 18 Squalling noise............................................................................220 Table 19 Various mechanical noises..................................................................221 Table 20 Exhaust odours.............................................................................222 Table 21 Diesel odours..............................................................................223 Table 22 Blue, white or black smoke.................................................................224 Table 23 Blue, black or white smoke when accelerating...............................................225 Fault Finding – Tests...................................................................................226 Test 1: Low Pressure Circuit Check..................................................................227 Test 2: Electrical Circuit Check....................................................................227 Test 3: Injector Check..............................................................................228 Test 4: Parameter Check.............................................................................228 Test 5: Air Inlet Circuit Check.....................................................................228 Test 6: ECM Check...................................................................................228 Test 7 High Pressure Pump Check.....................................................................229 Test 8: Diesel filter check.........................................................................229 Special Tool................................................................................................230 SECTION 6A2.....................................................................................................232 CONTENTS....................................................................................................232 Diagnosis Information and Procedure.........................................................................234 Diagnosis Table.........................................................................................234 Compression Check.......................................................................................234 Oil Pressure Check......................................................................................235 Valve Lash (Clearance)..................................................................................237 Measurement of valve lash (clearance)...............................................................237 Replacement of tappet...............................................................................237 Repair Instructions.........................................................................................239 Air Cleaner Element Removal and Installation............................................................239 Air Cleaner Element Inspection and Cleaning.............................................................239 Air Cleaner Assembly Removal and Installation...........................................................239 Cylinder Head Cover Components..........................................................................240 Cylinder Head Cover Removal and Installation............................................................240 Oil Pressure Switch Removal and Installation............................................................242 Heat Exchanger Removal and Installation.................................................................242 EGR Valve and Intake Pipe Components....................................................................244 EGR Valve and Intake Pipe Removal and Installation......................................................244 EGR Valve and Intake Pipe Inspection....................................................................247 Turbocharger Components.................................................................................248 Turbocharger Removal and Installation...................................................................249 Turbocharger Inspection.................................................................................251 Exhaust Manifold Components.............................................................................251 Exhaust Manifold Removal and Installation...............................................................252 Oil Pan and Oil Pump Strainer Components................................................................253 Oil Pan and Oil Pump Strainer Removal and Installation..................................................254 Engine Assembly Removal and Installation................................................................258 Timing Belt and Belt Tensioner Components...............................................................261 Timing Belt and Belt Tensioner Removal and Installation.................................................262 Timing Belt and Belt Tensioner Inspection...............................................................269 Oil Pump and Oil Pump Chain Components..................................................................270 Oil Pump and Oil Pump Chain Removal and Installation....................................................271 Oil Pump and Oil Pump Chain Inspection..................................................................273 Camshaft and Tappet Components..........................................................................274 Camshaft and Tappet Removal and Installation............................................................275 Camshaft and Tappet Inspection..........................................................................279 Valves and Cylinder Head Components.....................................................................283 Valves and Cylinder Head Assembly Removal and Installation..............................................283 Valves and Cylinder Head Assembly Inspection............................................................286 Valves and Cylinder Head Assembly Disassembly and Reassembly............................................286 Valves and Cylinder Head Components Inspection..........................................................289 Pistons, Piston Rings, Connecting Rods and Cylinders Components.........................................292 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation...........................293 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly.........................295 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection.........................................297 Main Bearings, Crankshaft and Cylinder Block Components.................................................302 Main Bearings, Crankshaft and Cylinder Block Removal and Installation...................................302 Main Bearings, Crankshaft and Cylinder Block Inspection.................................................309 Required Service Material...................................................................................312 Tightening Torque Specifications............................................................................312 Special Tool................................................................................................314 SECTION 6B2.....................................................................................................316 CONTENTS....................................................................................................316 General Description.........................................................................................317 Cooling System Circulation..............................................................................317 Degassing Tank..........................................................................................317 Water Pump..............................................................................................318 Thermostat..............................................................................................318 ECT sensor..............................................................................................318 Radiator Cooling Fan....................................................................................318 Diagnosis...................................................................................................319 Maintenance.................................................................................................320 Coolant.................................................................................................320 Coolant Level Check.....................................................................................321 Engine Cooling System Inspection and Service............................................................321 Coolant Replacement.....................................................................................323 On-Vehicle Service..........................................................................................326 Cooling System Component................................................................................326 Cooling Water Pipes or Hoses Removal and Installation...................................................327 Thermostat Assembly Removal and Installation............................................................327 Engine Coolant Temperature Sensor (ECT Sensor) Removal and Installation.................................328 Engine Coolant Temperature Sensor (ECT Sensor) Inspection...............................................328 Radiator Cooling Fan Removal and Installation...........................................................328 Radiator Cooling Fan motor On-Vehicle Inspection........................................................329 Radiator Cooling Fan Disassembly and Reassembly.........................................................330 Radiator Cooling Fan Relay Inspection...................................................................331 Radiator Removal and Installation.......................................................................331 Radiator Inspection.....................................................................................332 Water Pump Removal and Installation.....................................................................332 Water Pump Inspection...................................................................................333 Required Service Material...................................................................................334 Tightening Torque Specification.............................................................................334 SECTION 6C2.....................................................................................................336 CONTENTS....................................................................................................336 General Description.........................................................................................336 On-Vehicle Service..........................................................................................337 Fuel System Components..................................................................................337 Precautions.............................................................................................338 Water Draining of Fuel Filter...........................................................................339 Air Bleeding of Fuel System.............................................................................339 Fuel Line Inspection....................................................................................339 Fuel Filler Cap Inspection..............................................................................339 Fuel Tank Components....................................................................................340 Fuel Tank Removal and Installation......................................................................341 Fuel Tank Inspection....................................................................................343 Fuel Tank Purging Procedure.............................................................................343 Fuel Level Gauge Assembly Removal and Installation......................................................344 Fuel Pipe Removal and Installation......................................................................345 Fuel Level Gauge Inspection.............................................................................347 Fuel Filter Removal and Installation....................................................................347 Special Tool................................................................................................348 Tightening Torque Specification.............................................................................348 SECTION 6E2.....................................................................................................350 CONTENTS....................................................................................................350 General Description.........................................................................................352 System Diagram..........................................................................................352 Electronic Control System...............................................................................353 System wiring diagram...............................................................................353 System location diagram.............................................................................356 Air Intake System.......................................................................................357 Fuel Delivery System....................................................................................358 On-Vehicle Service..........................................................................................359 Idle Speed Inspection...................................................................................359 Fuel Delivery System....................................................................................360 Precautions in fuel delivery system.................................................................360 Fuel delivery system components.....................................................................363 Fuel pressure relief confirmation procedure.........................................................364 Fuel leakage check..................................................................................364 High pressure pipes removal and installation........................................................364 Fuel injector on-vehicle inspection.................................................................370 Fuel injector removal and installation..............................................................370 Common rail (High pressure fuel injection rail) removal and installation............................372 Injection pump removal and installation.............................................................373 Venturi removal and installation....................................................................375 Electronic Control System...............................................................................376 Engine control module (ECM) removal and installation................................................376 ECM registration....................................................................................377 Glow plug removal and installation..................................................................378 Glow plug inspection................................................................................378 PPS (accelerator pedal position sensor) removal and installation....................................379 PPS (accelerator pedal position sensor) inspection..................................................380 Fuel temperature sensor removal and installation....................................................381 Fuel temperature sensor inspection..................................................................382 Fuel flow actuator removal and installation.........................................................382 Fuel flow actuator inspection.......................................................................384 Engine coolant temperature sensor (ECT sensor) removal and installation.............................384 Engine coolant temperature sensor (ECT sensor) inspection...........................................385 Camshaft position sensor (CMP sensor) removal and installation......................................385 Crankshaft position (CKP) sensor (engine speed sensor) removal and installation.....................386 Crankshaft position (CKP) sensor (engine speed sensor) inspection...................................387 External air temperature sensor removal and installation............................................387 External air temperature sensor inspection..........................................................388 Intake air temperature (IAT) sensor removal and installation........................................389 Intake air temperature (IAT) sensor inspection......................................................389 Boost pressure sensor removal and installation......................................................390 Boost pressure sensor inspection....................................................................390 Radiator fan control system inspection..............................................................390 Main relay and radiator fan relay inspection........................................................391 Pre-heating unit removal and installation...........................................................391 Knock sensor removal and installation...............................................................392 EGR valve removal and installation..................................................................393 EGR valve inspection................................................................................393 Tightening Torque Specification.............................................................................394 Special Tool................................................................................................394 SECTION 6G2.....................................................................................................396 CONTENTS....................................................................................................396 General Description.........................................................................................397 Cranking System Circuit Diagram.........................................................................397 Diagnosis...................................................................................................397 Cranking System Symptom Diagnosis.......................................................................397 Cranking System Test....................................................................................399 Pull-in test........................................................................................399 Hold-in test........................................................................................399 Plunger and pinion return test......................................................................399 No-load performance test............................................................................400 ON-Vehicle Service..........................................................................................401 Starting Motor Dismounting and Remounting...............................................................401 Dismounting.........................................................................................401 Remounting..........................................................................................401 Tightening Torque Specification.............................................................................401 SECTION 6H2.....................................................................................................402 CONTENTS....................................................................................................402 General Description.........................................................................................403 Battery Description.....................................................................................403 Carrier and hold-down...............................................................................403 Electrolyte freezing................................................................................403 Sulfation...........................................................................................403 Built-in indicator (if equipped)....................................................................403 Care of battery.....................................................................................404 Generator Description...................................................................................405 Diagnosis...................................................................................................406 Battery Inspection......................................................................................406 Visual inspection...................................................................................406 Generator Symptom Diagnosis.............................................................................406 Charging indicator lamp operation...................................................................406 Undercharged battery................................................................................407 On-Vehicle Service..........................................................................................408 Jump Starting in Case of Emergency......................................................................408 With auxiliary (booster) battery....................................................................408 With charging equipment.............................................................................408 Battery Dismounting and Remounting...................................................................... 35 Dismounting.........................................................................................409 Handling............................................................................................409 Remounting.......................................................................................... 35 Generator Drive Belt Tensioner Components...............................................................410 Generator Drive Belt Removal and Installation...........................................................411 Generator Drive Belt Inspection.........................................................................411 Vacuum Pump Inspection..................................................................................411 Generator Dismounting and Remounting....................................................................412 Specification...............................................................................................413 Battery.................................................................................................413 Generator...............................................................................................413 Tightening Torque Specification.............................................................................413 Special Tools...............................................................................................413 SECTION 6K2.....................................................................................................414 CONTENTS....................................................................................................414 General Description.........................................................................................415 Maintenance.................................................................................................415 On-Vehicle Service..........................................................................................416 Exhaust System Components...............................................................................416 Exhaust Manifold Removal and Installation...............................................................417 Exhaust Manifold Inspection.............................................................................417 Exhaust Pipe Removal and Installation...................................................................417 Tightening Torque Specification.............................................................................417 SECTION 7A2.....................................................................................................418 CONTENTS....................................................................................................418 General Description.........................................................................................419 Transmission Components.................................................................................419 On-Vehicle Service..........................................................................................420 Manual Transmission Oil Change..........................................................................420 Extension Case Oil Seal Replacement.....................................................................421 Gear Shift Control Lever Assembly Components............................................................422 Gear Shift Control Lever Assembly Removal and Installation..............................................423 Gear Shift Control Lever Assembly Disassembly and Reassembly............................................424 Gear Shift Control Lever Assembly Inspection............................................................424 Unit Repair Overhaul........................................................................................425 Manual Transmission Unit Components.....................................................................425 Transmission Unit Dismounting and Remounting............................................................426 Gear Shift Lever Case Assembly Components...............................................................428 Gear Shift Lever Case Assembly Removal and Installation.................................................429 Gear Shift Lever Case Assembly Disassembly and Reassembly...............................................430 Back Up Lamp Switch Removal and Installation............................................................431 Back Up Lamp Switch Inspection..........................................................................431 Manual Transmission Assembly Components.................................................................432 Manual Transmission Assembly Disassembly and Reassembly.................................................433 Locating Spring Inspection..............................................................................438 Front Case Disassembly and Assembly.....................................................................439 Gear Shift Shaft and Fork Components....................................................................440 Gear Shift Fork Inspection..............................................................................440 Input Shaft, Countershaft and Output Shaft Components...................................................441 Input Shaft Assembly Disassembly and Reassembly.........................................................442 Input Shaft Assembly Inspection.........................................................................445 Countershaft Assembly Disassembly and Reassembly........................................................445 Countershaft Assembly Inspection........................................................................448 Output Shaft Assembly Disassembly and Reassembly........................................................448 Output Shaft Assembly Inspection........................................................................449 Tightening Torque Specification.............................................................................449 Required Service Material...................................................................................450 Special Tool................................................................................................451 SECTION 7C2.....................................................................................................452 CONTENTS....................................................................................................452 General Description.........................................................................................453 Diagnosis...................................................................................................454 Diagnosis Table.........................................................................................454 Clutch Pedal Inspection.................................................................................455 Clutch Fluid Level Check................................................................................455 On-Vehicle Service..........................................................................................456 Clutch Fluid Pipe and Hose Components...................................................................456 Clutch Fluid Pipe and Hose Removal and Installation.....................................................457 Clutch Fluid Pipe and Hose Inspection...................................................................458 Clutch Master Cylinder Removal and Installation.........................................................458 Clutch Operating Cylinder Removal and Installation......................................................460 Unit Repair Overhaul........................................................................................461 Clutch Master Cylinder Components.......................................................................461 Clutch Master Cylinder Disassembly and Assembly.........................................................462 Clutch Master Cylinder Inspection.......................................................................463 Clutch Operating Cylinder Components....................................................................463 Clutch Operating Cylinder Disassembly and Assembly......................................................464 Clutch Operating Cylinder Inspection....................................................................465 Clutch Pedal and Clutch Pedal Bracket Components........................................................465 Clutch Cover, Clutch Disc, Flywheel and Release Bearing Components......................................466 Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation........................467 Clutch Cover, Clutch Disc, Flywheel and Release Bearing Inspection......................................469 Tightening Torque Specification.............................................................................470 Required Service Material...................................................................................470 Special Tool................................................................................................470 SECTION 7D2.....................................................................................................472 CONTENTS....................................................................................................472 General Description.........................................................................................473 Transfer Cross Selection Diagram........................................................................473 Transfer Description....................................................................................474 Gear Shift Control System Operation.....................................................................474 Diagnosis...................................................................................................475 Transfer Diagnosis......................................................................................475 On-Vehicle Service..........................................................................................476 Transfer Gear Oil Change................................................................................476 4WD Switch Removal and Installation.....................................................................476 4WD Switch Inspection...................................................................................477 VSS Removal and Installation............................................................................477 Transfer Assembly Mounting Components...................................................................478 Transfer Assembly Dismounting and Remounting............................................................479 Unit Repair Overhaul........................................................................................481 Transfer Unit Components................................................................................481 Transfer Case Component.............................................................................481 Transfer Gear Component.............................................................................482 Transfer Shift Shaft Component......................................................................483 Transfer Shift Lever Component......................................................................484 Transfer Unit Disassembly and Reassembly................................................................485 Transfer Inspection.....................................................................................496 Front Case Assembly Disassembly and Reassembly..........................................................497 Rear Case Assembly Disassembly and Reassembly...........................................................499 Transfer Input Shaft Assembly Disassembly and Reassembly................................................500 Transfer Counter Gear Assembly Disassembly and Reassembly...............................................501 Reduction Shift Shaft Assembly Disassembly and Reassembly...............................................501 Reduction Shift Shaft Assembly Inspection...............................................................502 Front Drive Shift Shaft Assembly Disassembly and Reassembly.............................................502 Front Drive Shift Shaft Assembly Inspection.............................................................502 Transfer Output Rear Shaft Assembly Disassembly and Reassembly..........................................503 Transfer Output Front Shaft Assembly Disassembly and Reassembly.........................................504 Output Shaft Snap Ring Adjustment.......................................................................505 Tightening Torque Specification.............................................................................506 Required Service Material...................................................................................506 Special Tool................................................................................................507 SECTION 8.......................................................................................................508 CONTENTS....................................................................................................508 Diagnosis...................................................................................................510 Brake and Parking Brake Warning Light...................................................................510 On-Vehicle Service..........................................................................................511 Turn Signal and Hazard Warning Lights System............................................................511 Turn signal and hazard warning lights system circuit inspection.....................................511 Stop (Brake) Lamp.......................................................................................512 Stop (brake) lamp switch............................................................................512 Combination Meter.......................................................................................513 Fuel sender gauge...................................................................................515 Engine Coolant Temperature Meter and Sensor Unit........................................................515 Engine coolant temperature sensor...................................................................515 Oil Pressure Warning Light..............................................................................516 Oil pressure switch.................................................................................516 Brake and Parking Brake Warning Light...................................................................516 Indicator controller (for brake warning light)......................................................516 Brake vacuum switch.................................................................................517 Wiper and Washer........................................................................................517 Washer pump.........................................................................................518 Power Door Lock System (If Equipped)....................................................................519 Power door lock system circuit inspection...........................................................519 SECTION 8G2.....................................................................................................522 CONTENTS....................................................................................................522 General Description.........................................................................................523 Immobilizer Control System Description..................................................................523 Immobilizer Control System Wiring Circuit Diagram.......................................................523 Immobilizer Control System Components Location..........................................................524 On-Board Diagnostic System Description..................................................................524 Diagnosis...................................................................................................525 Precautions in Diagnosing Troubles......................................................................525 Precautions for Replacing ECM or Immobilizer Control Module.............................................525 Diagnostic Flow Table...................................................................................526 Diagnostic Trouble Code (DTC) Check.....................................................................527 Diagnostic Trouble Code (DTC) Clearance.................................................................527 Diagnostic Trouble Code (DTC) Table.....................................................................528 Scan Tool Data..........................................................................................528 Inspection of Immobilizer Control Module and Its Circuits...............................................529 DTC 16: Communication Line Between Immobilizer Control Module and Coil Antenna Shorted to Ground .......531 DTC 21: Communication Line Between Immobilizer Control Module and Coil Antenna Shorted to Power C.......533 DTC 70: Immobilizer Control Module Internal Failure.....................................................533 General Troubleshooting of Immobilizer Control System...................................................534 On-vehicle Service..........................................................................................536 Precautions in Handling Immobilizer Control System......................................................536 Immobilizer Control Module Removal and Installation.....................................................536 Coil Antenna Removal and Installation...................................................................537 Coil Antenna Inspection.................................................................................537 Registration Procedure of Immobilizer Control System Components.........................................538 Procedure to register ignition key..................................................................538 Procedure after Immobilizer Control Module replacement..............................................538 Procedure for ECM replacement.......................................................................538 Special Tools...............................................................................................539 SECTION 9.......................................................................................................540 CONTENTS....................................................................................................540 Body Structure..............................................................................................541 Under Body Dimensions...................................................................................541 SECTION 10B2....................................................................................................544 CONTENTS....................................................................................................544 General Description.........................................................................................546 System Components and Wiring Location View and Connectors...............................................546 System Wiring Diagram...................................................................................547 Diagnosis...................................................................................................548 DTC Table...............................................................................................548 DTC B1035 – Forward Sensor Circuit Open or Short to Power Circuit.......................................550 DTC B1036 – Forward Sensor Circuit Short Between Two Wires or Short to Ground...........................550 On-vehicle Service..........................................................................................553 Air bag wire harness and connector in instrument panel harness, floor harness and pretensioner ha.......553 Repairs and Inspections Required after an Accident......................................................553 Accident with Deployment / Activation - Component Replacement...........................................553 Accident with or without Deployment / Activation - Component Inspections................................554 Forward Sensor..........................................................................................556 Tightening Torque Specification.............................................................................558 Copyright.......................................................................................................560 Bookcover.......................................................................................................561
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