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Suzuki Swift RS Series Service Manual (Vol 1&2) – PDF DOWNLOAD
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Description
Suzuki Swift RS Series Service Manual (Vol 1&2) – PDF DOWNLOAD
FILE DETAILS:
Suzuki Swift RS Series Service Manual (Vol 1&2) – PDF DOWNLOAD
Language : English
Pages : 2234
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki Swift RS Series 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 assembly 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 (RS413/RS415/RS416/RS413D) on and after 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 Swift RS Series Service Manual (Vol 1&2) – PDF DOWNLOAD
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........................................................................................................................................................................................................................................ 10 Warning for Wheel (with tire) Removal...................................................................................................................................................................................................................... 13 Warning for Handling Emergency Flat Tire Repair Kit........................................................................................................................................................................................................ 13 Precautions for Catalytic Converter........................................................................................................................................................................................................................ 14 Precautions for Catalytic Converter and Diesel Particulate Filter (DPF‚) (Diesel Model).................................................................................................................................................................... 14 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................................................. 14 Precaution for CAN Communication System.................................................................................................................................................................................................................... 14 Precautions for Electrical Circuit Service................................................................................................................................................................................................................. 14 Air Bag Warning............................................................................................................................................................................................................................................ 16 Air Bag System Service Warning............................................................................................................................................................................................................................. 16 Fastener Caution........................................................................................................................................................................................................................................... 17 Suspension Caution......................................................................................................................................................................................................................................... 17 Wheels and Tires Caution................................................................................................................................................................................................................................... 17 Precaution for Vehicle Equipped with ESP‚ System........................................................................................................................................................................................................... 17 Brake Caution.............................................................................................................................................................................................................................................. 17 Repair Instructions............................................................................................................................................................................................................................................ 18 Electrical Circuit Inspection Procedure.................................................................................................................................................................................................................... 18 Intermittent and Poor Connection Inspection................................................................................................................................................................................................................ 20 General Information.................................................................................................................................................................................................................................................... 21 General Information................................................................................................................................................................................................................................................ 23 General Description............................................................................................................................................................................................................................................ 23 Abbreviations.............................................................................................................................................................................................................................................. 23 Symbols.................................................................................................................................................................................................................................................... 24 Wire Color Symbols......................................................................................................................................................................................................................................... 24 Fasteners Information...................................................................................................................................................................................................................................... 25 Vehicle Lifting Points..................................................................................................................................................................................................................................... 27 Engine Supporting Points................................................................................................................................................................................................................................... 29 Vehicle Identification Number.............................................................................................................................................................................................................................. 29 Engine Identification Number............................................................................................................................................................................................................................... 29 Transmission Identification Number (Petrol Engine Model)................................................................................................................................................................................................... 29 Component Location............................................................................................................................................................................................................................................. 30 Warning, Caution and Information Labels Location (Petrol Engine Model)..................................................................................................................................................................................... 30 Warning, Caution and Information Labels Location (Diesel Engine Model)..................................................................................................................................................................................... 32 Maintenance and Lubrication........................................................................................................................................................................................................................................ 34 Precautions.................................................................................................................................................................................................................................................... 34 Precautions for Maintenance and Lubrication................................................................................................................................................................................................................ 34 Scheduled Maintenance.......................................................................................................................................................................................................................................... 34 Maintenance Schedule under Normal Driving Conditions (Petrol Engine Model)................................................................................................................................................................................. 34 Maintenance Schedule under Normal Driving Conditions (Diesel Engine Model)................................................................................................................................................................................. 35 Maintenance Recommended under Severe Driving Conditions (Petrol Engine Model).............................................................................................................................................................................. 36 Maintenance Recommended under Severe Driving Conditions (Diesel Engine Model).............................................................................................................................................................................. 37 Repair Instructions............................................................................................................................................................................................................................................ 38 Accessory Drive Belt Inspection (Petrol Engine)............................................................................................................................................................................................................ 38 Engine accessory Drive Belt and Tensioner Inspection (Diesel Engine)....................................................................................................................................................................................... 39 Accessory Drive Belt Replacement (Petrol Engine)........................................................................................................................................................................................................... 39 Engine accessory Drive Belt Replacement (Diesel Engine).................................................................................................................................................................................................... 39 Valve Lash (Clearance) Inspection.......................................................................................................................................................................................................................... 39 Engine Oil and Filter Change (Petrol Engine)............................................................................................................................................................................................................... 39 Engine Oil and Filter Change (Diesel Engine)............................................................................................................................................................................................................... 41 Engine Coolant Change (Petrol Engine)...................................................................................................................................................................................................................... 42 Engine Coolant Change (Diesel Engine)...................................................................................................................................................................................................................... 42 Exhaust System Inspection.................................................................................................................................................................................................................................. 42 Spark Plug Replacement..................................................................................................................................................................................................................................... 43 Air Cleaner Filter Inspection (Petrol Engine).............................................................................................................................................................................................................. 43 Air Cleaner Filter Inspection (Diesel Engine).............................................................................................................................................................................................................. 43 Air Cleaner Filter Replacement (Petrol Engine)............................................................................................................................................................................................................. 43 Air Cleaner Filter Replacement (Diesel Engine)............................................................................................................................................................................................................. 43 Fuel Lines and Connections Inspection (Petrol Engine Model)................................................................................................................................................................................................ 43 Fuel Lines and Connections Inspection (Diesel Engine Model)................................................................................................................................................................................................ 43 Fuel Tank Inspection....................................................................................................................................................................................................................................... 44 Fuel Filter Replacement (Diesel Engine).................................................................................................................................................................................................................... 44 Water Draining of Fuel Filter (Diesel Engine).............................................................................................................................................................................................................. 44 PCV Valve Inspection....................................................................................................................................................................................................................................... 44 Fuel Evaporative Emission Control System Inspection........................................................................................................................................................................................................ 44 Brake Discs and Pads Inspection............................................................................................................................................................................................................................ 44 Brake Drums and Shoes (Rear) Inspection.................................................................................................................................................................................................................... 45 Brake Hoses and Pipes Inspection........................................................................................................................................................................................................................... 45 Brake Fluid Replacement.................................................................................................................................................................................................................................... 45 Brake Lever and Cable Inspection........................................................................................................................................................................................................................... 45 Clutch Fluid Inspection.................................................................................................................................................................................................................................... 46 Tires Inspection........................................................................................................................................................................................................................................... 46 Wheel Discs Inspection..................................................................................................................................................................................................................................... 46 Wheel Bearing Inspection................................................................................................................................................................................................................................... 46 Suspension System Inspection............................................................................................................................................................................................................................... 46 Steering System Inspection................................................................................................................................................................................................................................. 47 Drive Shaft (Axle) Boots Inspection........................................................................................................................................................................................................................ 47 Manual Transaxle Oil Inspection............................................................................................................................................................................................................................ 47 Manual Transaxle Oil Replacement........................................................................................................................................................................................................................... 48 Automatic Transaxle Fluid Level Inspection................................................................................................................................................................................................................. 48 Automatic Transaxle Fluid Replacement...................................................................................................................................................................................................................... 48 Automatic Transaxle Fluid Cooler Hose Inspection........................................................................................................................................................................................................... 48 All Latches, Hinges and Locks Inspection................................................................................................................................................................................................................... 48 Air Conditioning Filter (If Equipped) Inspection........................................................................................................................................................................................................... 49 Air Conditioning Filter (If Equipped) Replacement.......................................................................................................................................................................................................... 49 Final Inspection for Maintenance Service................................................................................................................................................................................................................... 49 Specifications................................................................................................................................................................................................................................................. 50 Tightening Torque Specifications........................................................................................................................................................................................................................... 50 Special Tools and Equipment.................................................................................................................................................................................................................................... 51 Recommended Fluids and Lubricants (Petrol Engine Model).................................................................................................................................................................................................... 51 Recommended Fluids and Lubricants (Diesel Engine Model).................................................................................................................................................................................................... 51 Special Tool............................................................................................................................................................................................................................................... 51 Engine................................................................................................................................................................................................................................................................. 53 Precautions........................................................................................................................................................................................................................................................ 62 M13A / M15A / M16A............................................................................................................................................................................................................................................. 62 Precautions................................................................................................................................................................................................................................................ 62 Precautions for Engine................................................................................................................................................................................................................................. 62 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 63 Precautions................................................................................................................................................................................................................................................ 63 Precautions for Engine................................................................................................................................................................................................................................. 63 Engine General Information and Diagnosis........................................................................................................................................................................................................................... 64 M13A / M15A / M16A............................................................................................................................................................................................................................................. 64 Precautions................................................................................................................................................................................................................................................ 64 Precautions on Engine Service.......................................................................................................................................................................................................................... 64 Precautions in Diagnosing Trouble...................................................................................................................................................................................................................... 64 Precautions of ECM Circuit Inspection.................................................................................................................................................................................................................. 65 Precautions of Electric Throttle Body System Calibration............................................................................................................................................................................................... 65 General Description........................................................................................................................................................................................................................................ 65 Statement on Cleanliness and Care...................................................................................................................................................................................................................... 65 Engine Diagnosis General Description................................................................................................................................................................................................................... 65 On-Board Diagnostic System Description................................................................................................................................................................................................................. 66 Engine and Emission Control System Description......................................................................................................................................................................................................... 68 CAN Communication System Description................................................................................................................................................................................................................... 68 Air Intake System Description.......................................................................................................................................................................................................................... 70 Electric Throttle Body System Description.............................................................................................................................................................................................................. 70 Description of Electric Throttle Body System Calibration............................................................................................................................................................................................... 71 Fuel Cut Control Description........................................................................................................................................................................................................................... 72 Generator Control System Description (M16A Engine)..................................................................................................................................................................................................... 72 Electronic Control System Description.................................................................................................................................................................................................................. 73 Engine and Emission Control Input / Output Table....................................................................................................................................................................................................... 74 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 75 Engine and Emission Control System Diagram............................................................................................................................................................................................................. 75 Engine and Emission Control System Flow Diagram........................................................................................................................................................................................................ 77 ECM Input / Output Circuit Diagram..................................................................................................................................................................................................................... 78 Component Location......................................................................................................................................................................................................................................... 82 Electronic Control System Components Location.......................................................................................................................................................................................................... 82 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 83 Engine and Emission Control System Check............................................................................................................................................................................................................... 83 Malfunction Indicator Lamp (MIL) Check................................................................................................................................................................................................................. 86 DTC Check.............................................................................................................................................................................................................................................. 87 DTC Clearance.......................................................................................................................................................................................................................................... 87 DTC Table.............................................................................................................................................................................................................................................. 88 Fail-Safe Table........................................................................................................................................................................................................................................ 93 Scan Tool Data......................................................................................................................................................................................................................................... 94 Visual Inspection...................................................................................................................................................................................................................................... 99 Engine Basic Inspection................................................................................................................................................................................................................................ 100 Engine Symptom Diagnosis............................................................................................................................................................................................................................... 103 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)........................................................................................................................................ 113 Malfunction Indicator Lamp Remains ON after Engine Starts.............................................................................................................................................................................................. 115 DTC P0010: Camshaft Position Actuator Circuit (VVT Model).............................................................................................................................................................................................. 117 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (VVT Model).............................................................................................................................................. 119 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)................................................................................................................................................................................... 121 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)................................................................................................................................................................................... 124 DTC P0101: Mass Air Flow Circuit Range / Performance................................................................................................................................................................................................... 126 DTC P0102: Mass Air Flow Circuit Low Input............................................................................................................................................................................................................. 130 DTC P0103: Mass Air Flow Circuit High Input............................................................................................................................................................................................................ 132 DTC P0106: Manifold Absolute Pressure Range / Performance.............................................................................................................................................................................................. 134 DTC P0107: Manifold Absolute Pressure Circuit Low Input................................................................................................................................................................................................ 136 DTC P0108: Manifold Absolute Pressure Circuit High Input............................................................................................................................................................................................... 138 DTC P0111: Intake Air Temperature Circuit Range / Performance.......................................................................................................................................................................................... 141 DTC P0112: Intake Air Temperature Sensor Circuit Low................................................................................................................................................................................................... 144 DTC P0113: Intake Air Temperature Sensor Circuit High.................................................................................................................................................................................................. 146 DTC P0116: Engine Coolant Temperature Circuit Range / Performance...................................................................................................................................................................................... 149 DTC P0117: Engine Coolant Temperature Circuit Low...................................................................................................................................................................................................... 152 DTC P0118: Engine Coolant Temperature Circuit High..................................................................................................................................................................................................... 154 DTC P0122: Throttle Position Sensor (Main) Circuit Low................................................................................................................................................................................................. 157 DTC P0123: Throttle Position Sensor (Main) Circuit High................................................................................................................................................................................................ 160 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)...................................................................................................................................................................... 163 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)........................................................................................................................................................................................... 166 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).................................................................................................................................................................................... 167 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)...................................................................................................................................................................... 170 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).................................................................................................................................................................................... 173 DTC P0171 / P0172: Fuel System Too Lean / Rich......................................................................................................................................................................................................... 175 DTC P0222: Throttle Position Sensor (Sub) Circuit Low.................................................................................................................................................................................................. 177 DTC P0223: Throttle Position Sensor (Sub) Circuit High................................................................................................................................................................................................. 180 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected................................................................................................................ 183 DTC P0327 / P0328: Knock Sensor Circuit Low / High..................................................................................................................................................................................................... 185 DTC P0335: Crankshaft Position (CKP) Sensor Circuit.................................................................................................................................................................................................... 187 DTC P0340: Camshaft Position (CMP) Sensor Circuit...................................................................................................................................................................................................... 190 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected........................................................................................................................................................... 193 DTC P0403: Exhaust Gas Recirculation Control Circuit................................................................................................................................................................................................... 196 DTC P0420: Catalyst System Efficiency below Threshold.................................................................................................................................................................................................. 198 DTC P0443: Evaporative Emission System Purge Control Valve Circuit..................................................................................................................................................................................... 200 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit................................................................................................................................................................................................ 202 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction...................................................................................................................................................................................................... 206 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low................................................................................................................................................................................................. 209 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High................................................................................................................................................................................................ 211 DTC P0601 / P0607: Internal Control Module Memory Check Sum Error / Control Module Performance......................................................................................................................................................... 213 DTC P0602: Control Module Programming Error............................................................................................................................................................................................................ 214 DTC P0616: Starter Relay Circuit Low................................................................................................................................................................................................................... 215 DTC P0617: Starter Relay Circuit High.................................................................................................................................................................................................................. 217 DTC P0620: Generator Control Circuit................................................................................................................................................................................................................... 219 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High......................................................................................................................................................................................... 221 DTC P1510: ECM Back-Up Power Supply Malfunction........................................................................................................................................................................................................ 223 DTC P1603: TCM Trouble Code Detected................................................................................................................................................................................................................... 224 DTC P1674: CAN Communication (Bus Off Error)........................................................................................................................................................................................................... 226 DTC P1675: CAN Communication (Transmission Error) (Automated Manual Transaxle Model)................................................................................................................................................................... 238 DTC P1676: CAN Communication (Reception Error for TCM (A/T or Automated Manual Transaxle model))....................................................................................................................................................... 243 DTC P1678: CAN Communication (Reception Error for BCM)................................................................................................................................................................................................. 247 DTC P1685: CAN Communication (Reception Error ABS / ESP‚ Control Module)............................................................................................................................................................................... 251 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance................................................................................................................................................................................. 254 DTC P2102: Throttle Actuator Control Motor Circuit Low................................................................................................................................................................................................. 256 DTC P2103: Throttle Actuator Control Motor Circuit High................................................................................................................................................................................................ 259 DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed.............................................................................................................................................................................. 260 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance................................................................................................................................................................................. 262 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input.............................................................................................................................................................................................. 264 DTC P2123: Pedal Position Sensor (Main) Circuit High Input............................................................................................................................................................................................. 267 DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input............................................................................................................................................................................................... 270 DTC P2128: Pedal Position Sensor (Sub) Circuit High Input.............................................................................................................................................................................................. 273 DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation................................................................................................................................................................................... 276 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation...................................................................................................................................................................................... 279 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction..................................................................................................................................................................................... 281 Inspection of ECM and Its Circuits..................................................................................................................................................................................................................... 282 ECM Power and Ground Circuit Check..................................................................................................................................................................................................................... 308 Fuel Injector Circuit Check............................................................................................................................................................................................................................ 311 Fuel Pump and Its Circuit Check........................................................................................................................................................................................................................ 313 Fuel Pressure Check.................................................................................................................................................................................................................................... 316 A/C System Circuits Check.............................................................................................................................................................................................................................. 318 Electric Load Signal Circuit Check..................................................................................................................................................................................................................... 321 Radiator cooling fan Low Speed Control System Check.................................................................................................................................................................................................... 323 Radiator cooling fan High Speed Control System Check................................................................................................................................................................................................... 325 Repair Instructions........................................................................................................................................................................................................................................ 328 Idle Speed and IAC Throttle Valve Opening Inspection................................................................................................................................................................................................... 328 Special Tools and Equipment................................................................................................................................................................................................................................ 329 Special Tool........................................................................................................................................................................................................................................... 329 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 330 Precautions................................................................................................................................................................................................................................................ 330 Precautions on Engine Service.......................................................................................................................................................................................................................... 330 Precautions in Diagnosing Trouble...................................................................................................................................................................................................................... 330 General Description........................................................................................................................................................................................................................................ 331 Statement on Cleanliness and Care...................................................................................................................................................................................................................... 331 Engine Diagnosis General Description................................................................................................................................................................................................................... 331 OBD System Description................................................................................................................................................................................................................................. 331 CAN Communication System Description................................................................................................................................................................................................................... 333 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 334 Electronic Control System Description.................................................................................................................................................................................................................. 334 ECM Input / Output Circuit Diagram..................................................................................................................................................................................................................... 336 Diesel Particulate Filter (DPF‚) Description........................................................................................................................................................................................................... 339 Diesel Particulate Filter (DPF‚) Regeneration Description.............................................................................................................................................................................................. 339 Oil Life Monitoring System (DPF‚ model)................................................................................................................................................................................................................ 340 Component Location......................................................................................................................................................................................................................................... 341 Electronic Control System Components Location.......................................................................................................................................................................................................... 341 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 342 Malfunction Indicator Lamp (MIL) Check................................................................................................................................................................................................................. 342 Service Vehicle Soon (SVS) Light Check................................................................................................................................................................................................................. 342 Engine and Emission Control System Check............................................................................................................................................................................................................... 343 DTC Check.............................................................................................................................................................................................................................................. 346 DTC Clearance.......................................................................................................................................................................................................................................... 346 DTC Confirmation Procedure............................................................................................................................................................................................................................. 347 DTC Table.............................................................................................................................................................................................................................................. 348 Fail-Safe Table........................................................................................................................................................................................................................................ 353 Scan Tool Data......................................................................................................................................................................................................................................... 357 Visual Inspection...................................................................................................................................................................................................................................... 363 Engine Basic Inspection................................................................................................................................................................................................................................ 364 Engine Symptom Diagnosis............................................................................................................................................................................................................................... 364 DTC P0030:............................................................................................................................................................................................................................................. 382 DTC P0088:............................................................................................................................................................................................................................................. 383 DTC P0090:............................................................................................................................................................................................................................................. 384 DTC P0093:............................................................................................................................................................................................................................................. 385 DTC P0100:............................................................................................................................................................................................................................................. 386 DTC P0106:............................................................................................................................................................................................................................................. 386 DTC P0107 / P0108:..................................................................................................................................................................................................................................... 387 DTC P0110:............................................................................................................................................................................................................................................. 388 DTC P0115:............................................................................................................................................................................................................................................. 389 DTC P0130 / P0135:..................................................................................................................................................................................................................................... 390 DTC P0168:............................................................................................................................................................................................................................................. 392 DTC P0180:............................................................................................................................................................................................................................................. 393 DTC P0190:............................................................................................................................................................................................................................................. 394 DTC P0201 / P0202 / P0203 / P0204:..................................................................................................................................................................................................................... 395 DTC P0217:............................................................................................................................................................................................................................................. 395 DTC P0219:............................................................................................................................................................................................................................................. 396 DTC P0230:............................................................................................................................................................................................................................................. 397 DTC P0235:............................................................................................................................................................................................................................................. 398 DTC P0243:............................................................................................................................................................................................................................................. 399 DTC P0335:............................................................................................................................................................................................................................................. 401 DTC P0340:............................................................................................................................................................................................................................................. 402 DTC P0380 / P0683:..................................................................................................................................................................................................................................... 404 DTC P0400:............................................................................................................................................................................................................................................. 405 DTC P0403:............................................................................................................................................................................................................................................. 406 DTC P0500:............................................................................................................................................................................................................................................. 407 DTC P0520:............................................................................................................................................................................................................................................. 408 DTC P0530:............................................................................................................................................................................................................................................. 409 DTC P0560:............................................................................................................................................................................................................................................. 410 DTC P0571:............................................................................................................................................................................................................................................. 411 DTC P0602:............................................................................................................................................................................................................................................. 412 DTC P0603:............................................................................................................................................................................................................................................. 413 DTC P0604:............................................................................................................................................................................................................................................. 413 DTC P0605:............................................................................................................................................................................................................................................. 414 DTC P0650:............................................................................................................................................................................................................................................. 414 DTC P0685 / P1625:..................................................................................................................................................................................................................................... 416 DTC P0704:............................................................................................................................................................................................................................................. 417 DTC P1093:............................................................................................................................................................................................................................................. 418 DTC P1105:............................................................................................................................................................................................................................................. 418 DTC P1120:............................................................................................................................................................................................................................................. 419 DTC P1122:............................................................................................................................................................................................................................................. 419 DTC 1180:.............................................................................................................................................................................................................................................. 420 DTC P1190:............................................................................................................................................................................................................................................. 421 DTC P1191:............................................................................................................................................................................................................................................. 422 DTC P1481:............................................................................................................................................................................................................................................. 423 DTC P1482 / P1483:..................................................................................................................................................................................................................................... 424 DTC P1530:............................................................................................................................................................................................................................................. 425 DTC P1571:............................................................................................................................................................................................................................................. 426 DTC P1600:............................................................................................................................................................................................................................................. 426 DTC P1620:............................................................................................................................................................................................................................................. 427 DTC P1635:............................................................................................................................................................................................................................................. 429 DTC P1639:............................................................................................................................................................................................................................................. 431 DTC P1660:............................................................................................................................................................................................................................................. 434 DTC P1725:............................................................................................................................................................................................................................................. 434 DTC P1811:............................................................................................................................................................................................................................................. 435 DTC P1901:............................................................................................................................................................................................................................................. 436 DTC P1902:............................................................................................................................................................................................................................................. 438 DTP P2003:............................................................................................................................................................................................................................................. 439 DTC P2146:............................................................................................................................................................................................................................................. 439 DTC P2237 / P2297:..................................................................................................................................................................................................................................... 440 DTC P2244:............................................................................................................................................................................................................................................. 441 DTC U2101:............................................................................................................................................................................................................................................. 441 DTC U2103:............................................................................................................................................................................................................................................. 442 DTC U2107:............................................................................................................................................................................................................................................. 443 DTC U2108:............................................................................................................................................................................................................................................. 443 DTC U2116:............................................................................................................................................................................................................................................. 444 Table A-1: Fuel Pump Relay Operation Check............................................................................................................................................................................................................. 444 Table A-2: Injector Circuit Check...................................................................................................................................................................................................................... 446 Table A-3: Fuel Temperature Sensor Check............................................................................................................................................................................................................... 448 Table A-4: Fuel Pressure Sensor Circuit Check.......................................................................................................................................................................................................... 448 Table A-5: Fuel Pressure Regulator Operation Check..................................................................................................................................................................................................... 449 Table A-6: Low-Pressure Fuel Supply Circuit Check...................................................................................................................................................................................................... 450 Table A-7: High-Pressure Fuel Supply Circuit Check..................................................................................................................................................................................................... 453 Table A-8: Fuel Heater Operation Check................................................................................................................................................................................................................. 455 Table B-1: Air Intake / Turbocharger Circuit Check..................................................................................................................................................................................................... 457 Table B-2: MAF Sensor Check............................................................................................................................................................................................................................ 458 Table B-3: Boost Pressure Sensor Check................................................................................................................................................................................................................. 459 Table B-4: Barometric Pressure Check................................................................................................................................................................................................................... 460 Table B-5: EGR Valve Operation Check................................................................................................................................................................................................................... 460 Table B-6: Boost Pressure Control Solenoid Valve Operation Check (DPF‚ Model).......................................................................................................................................................................... 461 Table B-7: DPF‚ Differential Pressure Sensor Check..................................................................................................................................................................................................... 462 Table B-8: Exhaust Gas Temperature (EGT) Sensor Check (DPF‚ Model)..................................................................................................................................................................................... 463 Table B-9: A/F Sensor Check (Non-DPF‚ Model)........................................................................................................................................................................................................... 464 Table C-1: Battery Voltage Check....................................................................................................................................................................................................................... 465 Table C-2: Main Relay Operation Check.................................................................................................................................................................................................................. 466 Table C-3: Engine Speed Check.......................................................................................................................................................................................................................... 466 Table C-4: ECT Sensor Check............................................................................................................................................................................................................................ 468 Table C-5: IAT Sensor Check............................................................................................................................................................................................................................ 468 Table C-6: Accelerator Pedal Check..................................................................................................................................................................................................................... 469 Table C-7: Speed Signal Check.......................................................................................................................................................................................................................... 471 Table C-8: Glow Plugs Operation Check.................................................................................................................................................................................................................. 471 Table C-9: Radiator Cooling Fan Operation Check........................................................................................................................................................................................................ 474 ECM and Its Circuits Voltage Value (for Reference)..................................................................................................................................................................................................... 477 Repair Instructions........................................................................................................................................................................................................................................ 488 Idle Speed Inspection.................................................................................................................................................................................................................................. 488 Special Tools and Equipment................................................................................................................................................................................................................................ 489 Special Tool........................................................................................................................................................................................................................................... 489 Aux. Emission Control Devices...................................................................................................................................................................................................................................... 490 M13A / M15A / M16A............................................................................................................................................................................................................................................. 490 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 490 EGR System Inspection.................................................................................................................................................................................................................................. 490 Repair Instructions........................................................................................................................................................................................................................................ 490 EVAP Canister Purge Inspection......................................................................................................................................................................................................................... 490 EVAP Canister Purge Valve and Its Circuit Inspection................................................................................................................................................................................................... 491 Vacuum Passage Inspection.............................................................................................................................................................................................................................. 492 Vacuum Hose and Purge Valve Chamber Inspection......................................................................................................................................................................................................... 492 EVAP Canister Purge Valve Inspection................................................................................................................................................................................................................... 492 EVAP Canister Inspection............................................................................................................................................................................................................................... 493 EGR Valve Removal and Installation..................................................................................................................................................................................................................... 493 EGR Valve Inspection................................................................................................................................................................................................................................... 493 PCV Hose Inspection.................................................................................................................................................................................................................................... 493 PCV Valve Inspection................................................................................................................................................................................................................................... 494 Special Tools and Equipment................................................................................................................................................................................................................................ 494 Special Tool........................................................................................................................................................................................................................................... 494 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 495 Repair Instructions........................................................................................................................................................................................................................................ 495 EGR Valve On-Vehicle Inspection........................................................................................................................................................................................................................ 495 EGR Valve Inspection................................................................................................................................................................................................................................... 495 Exhaust Gas Temperature (EGT) Sensor Removal and Installation (DPF‚ Model)............................................................................................................................................................................. 496 Exhaust Gas Temperature (EGT) Sensor Inspection (DPF‚ Model)........................................................................................................................................................................................... 496 DPF‚ Differential Pressure Sensor Removal and Installation............................................................................................................................................................................................. 497 DPF‚ Differential Pressure Sensor Inspection........................................................................................................................................................................................................... 497 Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection (Non-DPF‚ Model)..................................................................................................................................................................................... 498 Air Fuel Ratio (A/F) Sensor Removal and Installation (Non-DPF‚ Model).................................................................................................................................................................................. 498 Specifications............................................................................................................................................................................................................................................. 499 Tightening Torque Specifications....................................................................................................................................................................................................................... 499 Special Tools and Equipment................................................................................................................................................................................................................................ 499 Special Tool........................................................................................................................................................................................................................................... 499 Engine Electrical Devices.......................................................................................................................................................................................................................................... 500 M13A / M15A / M16A............................................................................................................................................................................................................................................. 500 Repair Instructions........................................................................................................................................................................................................................................ 500 Engine Control Module (ECM) Removal and Installation................................................................................................................................................................................................... 500 Manifold Absolute Pressure (MAP) Sensor Inspection..................................................................................................................................................................................................... 501 Electric Throttle Body Assembly On-Vehicle Inspection.................................................................................................................................................................................................. 501 Electric Throttle Body System Calibration.............................................................................................................................................................................................................. 504 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection................................................................................................................................................................................. 504 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation.............................................................................................................................................................................. 504 Accelerator Pedal Position (APP) Sensor Assembly Inspection (M16A and Automated Manual Transaxle Model)................................................................................................................................................ 506 Accelerator Pedal Position (APP) Sensor Assembly Inspection (M13A and M15A without Automated Manual Transaxle Model)................................................................................................................................... 506 Engine Coolant Temperature (ECT) Sensor Removal and Installation....................................................................................................................................................................................... 507 Engine Coolant Temperature (ECT) Sensor Inspection..................................................................................................................................................................................................... 507 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection.................................................................................................................................................................................. 508 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation...................................................................................................................................................................................... 508 Camshaft Position (CMP) Sensor Removal and Installation................................................................................................................................................................................................ 509 Camshaft Position (CMP) Sensor Inspection.............................................................................................................................................................................................................. 509 Crankshaft Position (CKP) Sensor Removal and Installation.............................................................................................................................................................................................. 510 Crankshaft Position (CKP) Sensor Inspection............................................................................................................................................................................................................ 510 Vehicle Speed Sensor (VSS) Inspection (If Equipped).................................................................................................................................................................................................... 511 Knock Sensor Removal and Installation.................................................................................................................................................................................................................. 511 Main Relay, Fuel Pump Relay, Starting Motor Control Relay and Throttle Actuator Control Relay Inspection............................................................................................................................................... 512 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection...................................................................................................................................................................... 512 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation................................................................................................................................................................... 513 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection................................................................................................................................................................................. 513 Specifications............................................................................................................................................................................................................................................. 514 Tightening Torque Specifications....................................................................................................................................................................................................................... 514 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 515 Precautions................................................................................................................................................................................................................................................ 515 Precaution in Replacing ECM............................................................................................................................................................................................................................ 515 General Description........................................................................................................................................................................................................................................ 515 ECM Registration....................................................................................................................................................................................................................................... 515 Repair Instructions........................................................................................................................................................................................................................................ 516 Engine Control Module (ECM) Removal and Installation................................................................................................................................................................................................... 516 Registration for ECM Replacement....................................................................................................................................................................................................................... 517 Fuel Injector Registration............................................................................................................................................................................................................................. 518 A/F Data Initialization (Non-DPF‚ Model)............................................................................................................................................................................................................... 518 DPF‚ Data Initialization............................................................................................................................................................................................................................... 518 DPF‚ Differential Pressure Sensor Data Initialization.................................................................................................................................................................................................. 518 Catalytic Converter Data Initialization (DPF‚ Model)................................................................................................................................................................................................... 518 DPF‚ After-sales Regeneration.......................................................................................................................................................................................................................... 518 After-sales Regeneration Failure....................................................................................................................................................................................................................... 520 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation................................................................................................................................................................... 520 Glow Plug Removal and Installation..................................................................................................................................................................................................................... 521 Glow Plug Inspection................................................................................................................................................................................................................................... 521 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection................................................................................................................................................................................. 522 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation.............................................................................................................................................................................. 522 Accelerator Pedal Position (APP) Sensor Assembly Inspection............................................................................................................................................................................................ 523 Engine Coolant Temperature (ECT) Sensor Removal and Installation....................................................................................................................................................................................... 523 Engine Coolant Temperature (ECT) Sensor Inspection..................................................................................................................................................................................................... 524 Camshaft Position (CMP) Sensor Removal and Installation................................................................................................................................................................................................ 524 Crankshaft Position (CKP) Sensor (Engine Speed Sensor) Removal and Installation........................................................................................................................................................................ 525 Crankshaft Position (CKP) Sensor (Engine Speed Sensor) Inspection...................................................................................................................................................................................... 525 Boost Pressure Sensor Removal and Installation......................................................................................................................................................................................................... 526 Fuel Pump Relay, Starting Motor Control Relay, Main Relay and Fuel Heater Relay Inspection............................................................................................................................................................. 526 Glow Plug Control Module Removal and Installation...................................................................................................................................................................................................... 527 Boost Pressure Control Solenoid Valve Removal and Installation (DPF‚ Model)............................................................................................................................................................................ 527 Boost Pressure Control Solenoid Valve Inspection (DPF‚ Model).......................................................................................................................................................................................... 527 Specifications............................................................................................................................................................................................................................................. 528 Tightening Torque Specifications....................................................................................................................................................................................................................... 528 Special Tools and Equipment................................................................................................................................................................................................................................ 528 Special Tool........................................................................................................................................................................................................................................... 528 Engine Mechanical.................................................................................................................................................................................................................................................. 529 M13A / M15A / M16A............................................................................................................................................................................................................................................. 529 General Description........................................................................................................................................................................................................................................ 529 Engine Construction Description........................................................................................................................................................................................................................ 529 Camshaft Position Control (VVT Variable Valve Timing) System Description............................................................................................................................................................................... 531 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 533 Compression Check...................................................................................................................................................................................................................................... 533 Engine Vacuum Check.................................................................................................................................................................................................................................... 534 Valve Lash (Clearance) Inspection...................................................................................................................................................................................................................... 535 Repair Instructions........................................................................................................................................................................................................................................ 538 Air Cleaner Components................................................................................................................................................................................................................................. 538 Air Cleaner Element Removal and Installation........................................................................................................................................................................................................... 538 Air Cleaner Element Inspection and Cleaning............................................................................................................................................................................................................ 539 Cylinder Head Cover Removal and Installation........................................................................................................................................................................................................... 539 Throttle Body and Intake Manifold Components........................................................................................................................................................................................................... 541 Throttle Body On-Vehicle Inspection.................................................................................................................................................................................................................... 542 Electric Throttle Body Assembly Removal and Installation............................................................................................................................................................................................... 542 Throttle Body Cleaning................................................................................................................................................................................................................................. 543 Intake Manifold Removal and Installation (For M16A Engine Model)....................................................................................................................................................................................... 543 Intake Manifold Removal and Installation (For Other Than M16A Engine Model)............................................................................................................................................................................ 545 Engine Mountings Components (For M16A Engine Model).................................................................................................................................................................................................... 546 Engine Mountings Components (For Other Than M16A Engine Model)......................................................................................................................................................................................... 547 Engine Assembly Removal and Installation (For M16A Engine Model)....................................................................................................................................................................................... 548 Engine Assembly Removal and Installation (For Other Than M16A Engine Model)............................................................................................................................................................................ 551 Timing Chain Cover Components.......................................................................................................................................................................................................................... 555 Timing Chain Cover Removal and Installation............................................................................................................................................................................................................ 556 Timing Chain Cover Inspection.......................................................................................................................................................................................................................... 558 Oil Control Valve Removal and Installation (For Engine with VVT)....................................................................................................................................................................................... 558 Oil Control Valve Inspection (For Engine with VVT)..................................................................................................................................................................................................... 559 Timing Chain and Chain Tensioner Components............................................................................................................................................................................................................ 559 Timing Chain and Chain Tensioner Removal and Installation.............................................................................................................................................................................................. 560 Timing Chain and Chain Tensioner Inspection............................................................................................................................................................................................................ 563 Camshaft, Tappet and Shim Components................................................................................................................................................................................................................... 565 Camshaft, Tappet and Shim Removal and Installation..................................................................................................................................................................................................... 566 Camshaft, Tappet and Shim Inspection................................................................................................................................................................................................................... 568 Valves and Cylinder Head Components.................................................................................................................................................................................................................... 572 Valves and Cylinder Head Removal and Installation...................................................................................................................................................................................................... 573 Valves and Cylinder Head Disassembly and Assembly...................................................................................................................................................................................................... 575 Valves and Valve Guides Inspection..................................................................................................................................................................................................................... 577 Cylinder Head Inspection............................................................................................................................................................................................................................... 580 Valve Spring Inspection................................................................................................................................................................................................................................ 581 Pistons, Piston Rings, Connecting Rods and Cylinders Components........................................................................................................................................................................................ 582 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation.......................................................................................................................................................................... 583 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly.......................................................................................................................................................................... 584 Cylinders, Pistons and Piston Rings Inspection......................................................................................................................................................................................................... 586 Piston Pins and Connecting Rods Inspection............................................................................................................................................................................................................. 588 Crank Pin and Connecting Rod Bearings Inspection....................................................................................................................................................................................................... 590 Main Bearings, Crankshaft and Cylinder Block Components................................................................................................................................................................................................ 593 Main Bearings, Crankshaft and Cylinder Block Removal and Installation.................................................................................................................................................................................. 594 Crankshaft Inspection.................................................................................................................................................................................................................................. 597 Main Bearings Inspection............................................................................................................................................................................................................................... 599 Sensor Plate Inspection................................................................................................................................................................................................................................ 605 Rear Oil Seal Inspection............................................................................................................................................................................................................................... 605 Flywheel Inspection.................................................................................................................................................................................................................................... 605 Cylinder Block Inspection.............................................................................................................................................................................................................................. 605 Specifications............................................................................................................................................................................................................................................. 606 Tightening Torque Specifications....................................................................................................................................................................................................................... 606 Special Tools and Equipment................................................................................................................................................................................................................................ 607 Recommended Service Material........................................................................................................................................................................................................................... 607 Special Tool........................................................................................................................................................................................................................................... 608 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 610 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 610 Compression Check...................................................................................................................................................................................................................................... 610 Timing Check........................................................................................................................................................................................................................................... 611 Repair Instructions........................................................................................................................................................................................................................................ 612 Air Cleaner Components................................................................................................................................................................................................................................. 612 Air Cleaner Filter Removal and Installation............................................................................................................................................................................................................ 613 Air Cleaner Filter Inspection and Cleaning............................................................................................................................................................................................................. 613 Air Cleaner Assembly Removal and Installation.......................................................................................................................................................................................................... 613 Intercooler Components................................................................................................................................................................................................................................. 614 Intercooler Removal and Installation................................................................................................................................................................................................................... 614 Vacuum Pump Removal and Installation................................................................................................................................................................................................................... 615 Vacuum Pump Inspection................................................................................................................................................................................................................................. 616 EGR Valve and EGR Cooler Components.................................................................................................................................................................................................................... 616 EGR Valve and EGR Cooler Removal and Installation...................................................................................................................................................................................................... 617 Crankcase Ventilation System Component................................................................................................................................................................................................................. 618 Oil Separator and Crankcase Ventilation Cover Removal and Installation................................................................................................................................................................................. 618 Turbocharger Components................................................................................................................................................................................................................................ 620 Turbocharger Removal and Installation.................................................................................................................................................................................................................. 621 Turbocharger Inspection................................................................................................................................................................................................................................ 624 Intake Manifold Components............................................................................................................................................................................................................................. 625 Intake Manifold Removal and Installation............................................................................................................................................................................................................... 626 Engine Mounting Components............................................................................................................................................................................................................................. 628 Engine Assembly Removal and Installation............................................................................................................................................................................................................... 629 Timing Chain Cover and Timing Chain Components......................................................................................................................................................................................................... 632 Timing Chain Cover and Timing Chain Removal and Installation........................................................................................................................................................................................... 633 Timing Chain Cover and Timing Chain Inspection......................................................................................................................................................................................................... 638 Camshaft Housing Components............................................................................................................................................................................................................................ 640 Camshaft Housing Assembly Removal and Installation..................................................................................................................................................................................................... 641 Camshaft Housing Assembly Disassembly and Reassembly................................................................................................................................................................................................... 642 Camshaft Inspection.................................................................................................................................................................................................................................... 645 Valve and Cylinder Head Components..................................................................................................................................................................................................................... 647 Valve and Cylinder Head Assembly Removal and Installation.............................................................................................................................................................................................. 648 Valve and Cylinder Head Assembly Disassembly and Reassembly............................................................................................................................................................................................ 651 Valves and Guides Inspection........................................................................................................................................................................................................................... 653 Cylinder Head Inspection............................................................................................................................................................................................................................... 654 Valve Springs Inspection............................................................................................................................................................................................................................... 654 Piston, Piston Ring, Connecting Rod and Cylinder Components............................................................................................................................................................................................ 655 Pistons, Piston Rings, Connecting Rods and Cylinder Removal and Installation........................................................................................................................................................................... 656 Pistons, Piston Rings, Connecting Rods and Cylinder Disassembly and Reassembly......................................................................................................................................................................... 658 Cylinders, Pistons and Piston Rings Inspection......................................................................................................................................................................................................... 659 Piston Pins and Connecting Rods Inspection............................................................................................................................................................................................................. 661 Crank Pin and Connecting Rod Bearings Inspection....................................................................................................................................................................................................... 661 Main Bearing, Crankshaft and Cylinder Block Components................................................................................................................................................................................................. 665 Main Bearing, Crankshaft and Cylinder Block Removal and Installation................................................................................................................................................................................... 665 Main Bearing, Crankshaft and Cylinder Block Inspection................................................................................................................................................................................................. 669 Main Bearings Inspection............................................................................................................................................................................................................................... 670 Cylinder Block Inspection.............................................................................................................................................................................................................................. 674 Specifications............................................................................................................................................................................................................................................. 675 Tightening Torque Specifications....................................................................................................................................................................................................................... 675 Special Tools and Equipment................................................................................................................................................................................................................................ 676 Recommended Service Material........................................................................................................................................................................................................................... 676 Special Tool........................................................................................................................................................................................................................................... 676 Engine Lubrication System.......................................................................................................................................................................................................................................... 678 M13A / M15A / M16A............................................................................................................................................................................................................................................. 678 General Description........................................................................................................................................................................................................................................ 678 Engine Lubrication Description......................................................................................................................................................................................................................... 678 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 680 Oil Pressure Check..................................................................................................................................................................................................................................... 680 Repair Instructions........................................................................................................................................................................................................................................ 681 Heat Exchanger Components (For M16A Engine Model)...................................................................................................................................................................................................... 681 Heat Exchanger On-Vehicle Inspection (For M16A Engine Model)........................................................................................................................................................................................... 682 Heat Exchanger Removal and Installation (For M16A Engine Model)........................................................................................................................................................................................ 682 Oil Pan and Oil Pump Strainer Components............................................................................................................................................................................................................... 683 Oil Pan and Oil Pump Strainer Removal and Installation................................................................................................................................................................................................. 683 Oil Pan and Oil Pump Strainer Cleaning................................................................................................................................................................................................................. 685 Oil Pump Components.................................................................................................................................................................................................................................... 685 Oil Pump Removal and Installation...................................................................................................................................................................................................................... 686 Oil Pump Disassembly and Reassembly.................................................................................................................................................................................................................... 686 Oil Pump Inspection.................................................................................................................................................................................................................................... 687 Specifications............................................................................................................................................................................................................................................. 688 Tightening Torque Specifications....................................................................................................................................................................................................................... 688 Special Tools and Equipment................................................................................................................................................................................................................................ 689 Recommended Service Material........................................................................................................................................................................................................................... 689 Special Tool........................................................................................................................................................................................................................................... 689 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 690 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 690 Oil Pressure Check..................................................................................................................................................................................................................................... 690 Repair Instructions........................................................................................................................................................................................................................................ 691 Oil Pressure Switch On-Vehicle Inspection.............................................................................................................................................................................................................. 691 Oil Pressure Switch Removal and Installation........................................................................................................................................................................................................... 691 Oil Cooler Components.................................................................................................................................................................................................................................. 692 Oil Cooler Removal and Installation.................................................................................................................................................................................................................... 692 Oil Pan Components..................................................................................................................................................................................................................................... 694 Oil Pan Removal and Installation....................................................................................................................................................................................................................... 694 Oil Pump / Oil Pump Strainer Components................................................................................................................................................................................................................ 695 Oil Pump / Oil Pump Strainer Removal and Installation.................................................................................................................................................................................................. 696 Oil Pump Disassembly and Reassembly.................................................................................................................................................................................................................... 696 Oil Pump Strainer Cleaning............................................................................................................................................................................................................................. 696 Oil Pump Inspection.................................................................................................................................................................................................................................... 697 Specifications............................................................................................................................................................................................................................................. 698 Tightening Torque Specifications....................................................................................................................................................................................................................... 698 Special Tools and Equipment................................................................................................................................................................................................................................ 698 Recommended Service Material........................................................................................................................................................................................................................... 698 Special Tool........................................................................................................................................................................................................................................... 698 Engine Cooling System.............................................................................................................................................................................................................................................. 699 M13A / M15A / M16A............................................................................................................................................................................................................................................. 699 General Description........................................................................................................................................................................................................................................ 699 Cooling System Description............................................................................................................................................................................................................................. 699 Coolant Description.................................................................................................................................................................................................................................... 699 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 701 Coolant Circulation.................................................................................................................................................................................................................................... 701 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 702 Engine Cooling Symptom Diagnosis....................................................................................................................................................................................................................... 702 Repair Instructions........................................................................................................................................................................................................................................ 703 Cooling System Components.............................................................................................................................................................................................................................. 703 Coolant Level Check.................................................................................................................................................................................................................................... 705 Engine Cooling System Inspection and Cleaning.......................................................................................................................................................................................................... 705 Cooling System Draining................................................................................................................................................................................................................................ 705 Cooling System Flush and Refill........................................................................................................................................................................................................................ 706 Cooling Water Pipes or Hoses Removal and Installation.................................................................................................................................................................................................. 707 Thermostat Removal and Installation.................................................................................................................................................................................................................... 707 Thermostat Inspection.................................................................................................................................................................................................................................. 707 Radiator Cooling Fan Motor On-Vehicle Inspection....................................................................................................................................................................................................... 708 Radiator Cooling Fan Relay Inspection.................................................................................................................................................................................................................. 708 Radiator Cooling Fan Removal and Installation.......................................................................................................................................................................................................... 709 Radiator On-Vehicle Inspection and Cleaning............................................................................................................................................................................................................ 709 Radiator Removal and Installation...................................................................................................................................................................................................................... 709 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.................................................................................................................................................................................... 709 Water Pump / Generator Drive Belt Removal and Installation............................................................................................................................................................................................. 709 Water Pump Removal and Installation.................................................................................................................................................................................................................... 710 Water Pump Inspection.................................................................................................................................................................................................................................. 710 Specifications............................................................................................................................................................................................................................................. 711 Tightening Torque Specifications....................................................................................................................................................................................................................... 711 Special Tools and Equipment................................................................................................................................................................................................................................ 711 Recommended Service Material........................................................................................................................................................................................................................... 711 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 712 General Description........................................................................................................................................................................................................................................ 712 Cooling System Description............................................................................................................................................................................................................................. 712 Coolant Description.................................................................................................................................................................................................................................... 712 Coolant Degassing Tank Description..................................................................................................................................................................................................................... 712 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 713 Coolant Circulation.................................................................................................................................................................................................................................... 713 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 714 Engine Cooling Symptom Diagnosis....................................................................................................................................................................................................................... 714 Radiator Fan Control System Inspection................................................................................................................................................................................................................. 715 Repair Instructions........................................................................................................................................................................................................................................ 716 Cooling System Components.............................................................................................................................................................................................................................. 716 Coolant Level Check.................................................................................................................................................................................................................................... 717 Engine Cooling System Inspection and Cleaning.......................................................................................................................................................................................................... 717 Cooling System Draining................................................................................................................................................................................................................................ 718 Cooling System Refill.................................................................................................................................................................................................................................. 718 Cooling System Flush and Refill........................................................................................................................................................................................................................ 718 Cooling Water Pipes or Hoses Removal and Installation.................................................................................................................................................................................................. 719 Thermostat Assembly Removal and Installation........................................................................................................................................................................................................... 719 Radiator Cooling Fan Assembly On-Vehicle Inspection.................................................................................................................................................................................................... 720 Radiator Cooling Fan Relay Inspection.................................................................................................................................................................................................................. 720 Radiator Cooling Fan Assembly Removal and Installation................................................................................................................................................................................................. 721 Radiator Cooling Fan Disassembly and Reassembly........................................................................................................................................................................................................ 722 Radiator On-Vehicle Inspection and Cleaning............................................................................................................................................................................................................ 722 Radiator Removal and Installation...................................................................................................................................................................................................................... 722 Accessory Drive Belt On-Vehicle Inspection............................................................................................................................................................................................................. 723 Accessory Drive Belt Tension Inspection................................................................................................................................................................................................................ 723 Accessory Drive Belt Removal and Installation.......................................................................................................................................................................................................... 723 Accessory Drive Belt Tensioner Removal and Installation................................................................................................................................................................................................ 723 Water Pump Removal and Installation.................................................................................................................................................................................................................... 724 Water Pump Inspection.................................................................................................................................................................................................................................. 724 Specifications............................................................................................................................................................................................................................................. 725 Tightening Torque Specifications....................................................................................................................................................................................................................... 725 Fuel System........................................................................................................................................................................................................................................................ 726 M13A / M15A / M16A............................................................................................................................................................................................................................................. 726 Precautions................................................................................................................................................................................................................................................ 726 Precautions on Fuel System Service..................................................................................................................................................................................................................... 726 General Description........................................................................................................................................................................................................................................ 727 Fuel System Description................................................................................................................................................................................................................................ 727 Fuel Delivery System Description....................................................................................................................................................................................................................... 727 Fuel Pump Description.................................................................................................................................................................................................................................. 727 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 728 Fuel Delivery System Diagram........................................................................................................................................................................................................................... 728 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 728 Fuel Pressure Inspection............................................................................................................................................................................................................................... 728 Fuel Cut Operation Inspection.......................................................................................................................................................................................................................... 729 Repair Instructions........................................................................................................................................................................................................................................ 730 Fuel System Components................................................................................................................................................................................................................................. 730 Fuel Hose Disconnecting and Reconnecting............................................................................................................................................................................................................... 731 Fuel Pressure Relief Procedure......................................................................................................................................................................................................................... 733 Fuel Leakage Check Procedure........................................................................................................................................................................................................................... 733 Fuel Lines On-Vehicle Inspection....................................................................................................................................................................................................................... 733 Fuel Pipe Removal and Installation..................................................................................................................................................................................................................... 734 Fuel Injector On-Vehicle Inspection.................................................................................................................................................................................................................... 734 Fuel Injector Removal and Installation................................................................................................................................................................................................................. 735 Fuel Injector Inspection............................................................................................................................................................................................................................... 736 Fuel Filler Cap Inspection............................................................................................................................................................................................................................. 737 Fuel Tank Removal and Installation..................................................................................................................................................................................................................... 737 Fuel Tank Inspection................................................................................................................................................................................................................................... 739 Fuel Tank Purging Procedure............................................................................................................................................................................................................................ 739 Fuel Pump On-Vehicle Inspection........................................................................................................................................................................................................................ 739 Fuel Pump Assembly Removal and Installation............................................................................................................................................................................................................ 740 Fuel Pump Inspection................................................................................................................................................................................................................................... 741 Specifications............................................................................................................................................................................................................................................. 741 Tightening Torque Specifications....................................................................................................................................................................................................................... 741 Special Tools and Equipment................................................................................................................................................................................................................................ 742 Special Tool........................................................................................................................................................................................................................................... 742 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 743 Precautions................................................................................................................................................................................................................................................ 743 Precautions on Fuel System Service..................................................................................................................................................................................................................... 743 General Description........................................................................................................................................................................................................................................ 747 Fuel System Description................................................................................................................................................................................................................................ 747 Repair Instructions........................................................................................................................................................................................................................................ 748 Fuel Hose Disconnecting and Reconnecting............................................................................................................................................................................................................... 748 Fuel Pressure Relief Procedure......................................................................................................................................................................................................................... 750 Fuel Leakage Check Procedure........................................................................................................................................................................................................................... 750 Water Draining of Fuel Filter.......................................................................................................................................................................................................................... 750 Air Bleeding of Fuel System............................................................................................................................................................................................................................ 750 Fuel System Components................................................................................................................................................................................................................................. 751 High-Pressure Pipe Removal and Installation............................................................................................................................................................................................................ 753 Fuel Injector On-Vehicle Inspection.................................................................................................................................................................................................................... 754 Fuel Injector Removal and Installation................................................................................................................................................................................................................. 755 Common Rail Removal and Installation................................................................................................................................................................................................................... 757 High Pressure Pump Removal and Installation............................................................................................................................................................................................................ 757 Fuel Pressure Sensor Removal and Installation.......................................................................................................................................................................................................... 759 Fuel Pressure Regulator Removal and Installation....................................................................................................................................................................................................... 759 Fuel Pressure Regulator Inspection..................................................................................................................................................................................................................... 760 Fuel Lines and Connections Inspection.................................................................................................................................................................................................................. 760 Fuel Pipe Removal and Installation..................................................................................................................................................................................................................... 760 Fuel Filler Cap Inspection............................................................................................................................................................................................................................. 761 Fuel Tank On-Vehicle Inspection........................................................................................................................................................................................................................ 761 Fuel Tank Removal and Installation..................................................................................................................................................................................................................... 762 Fuel Tank Inspection................................................................................................................................................................................................................................... 764 Fuel Tank Purging Procedure............................................................................................................................................................................................................................ 764 Fuel Pump On-Vehicle Inspection........................................................................................................................................................................................................................ 764 Fuel Pump Assembly Removal and Installation............................................................................................................................................................................................................ 764 Fuel Pump Inspection................................................................................................................................................................................................................................... 765 Fuel Level Sensor Inspection........................................................................................................................................................................................................................... 766 Fuel Filter Element Removal and Installation........................................................................................................................................................................................................... 766 Fuel Filter Assembly Removal and Installation.......................................................................................................................................................................................................... 767 Fuel Heater and Fuel Temperature Sensor Removal and Installation....................................................................................................................................................................................... 767 Fuel Heater and Fuel Temperature Sensor Inspection..................................................................................................................................................................................................... 768 Specifications............................................................................................................................................................................................................................................. 768 Tightening Torque Specifications....................................................................................................................................................................................................................... 768 Special Tools and Equipment................................................................................................................................................................................................................................ 769 Special Tool........................................................................................................................................................................................................................................... 769 Ignition System.................................................................................................................................................................................................................................................... 770 M13A / M15A / M16A............................................................................................................................................................................................................................................. 770 General Description........................................................................................................................................................................................................................................ 770 Ignition System Construction........................................................................................................................................................................................................................... 770 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 771 Ignition System Wiring Circuit Diagram................................................................................................................................................................................................................. 771 Component Location......................................................................................................................................................................................................................................... 772 Ignition System Components Location.................................................................................................................................................................................................................... 772 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 773 Ignition System Symptom Diagnosis...................................................................................................................................................................................................................... 773 Reference Waveform of Ignition System.................................................................................................................................................................................................................. 773 Ignition System Check.................................................................................................................................................................................................................................. 773 Ignition Spark Test.................................................................................................................................................................................................................................... 775 Repair Instructions........................................................................................................................................................................................................................................ 775 High-Tension Cord Removal and Installation............................................................................................................................................................................................................. 775 High-Tension Cord Inspection........................................................................................................................................................................................................................... 776 Spark Plug Removal and Installation.................................................................................................................................................................................................................... 776 Spark Plug Inspection.................................................................................................................................................................................................................................. 776 Ignition Coil Assembly (Including ignitor) Removal and Installation.................................................................................................................................................................................... 777 Ignition Coil Assembly (Including ignitor) Inspection.................................................................................................................................................................................................. 777 Ignition Timing Inspection............................................................................................................................................................................................................................. 777 Specifications............................................................................................................................................................................................................................................. 778 Tightening Torque Specifications....................................................................................................................................................................................................................... 778 Special Tools and Equipment................................................................................................................................................................................................................................ 779 Special Tool........................................................................................................................................................................................................................................... 779 Starting System.................................................................................................................................................................................................................................................... 780 M13A / M15A / M16A............................................................................................................................................................................................................................................. 780 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 780 Cranking System Circuit Diagram........................................................................................................................................................................................................................ 780 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 780 Cranking System Symptom Diagnosis...................................................................................................................................................................................................................... 780 Cranking System Test................................................................................................................................................................................................................................... 782 Repair Instructions........................................................................................................................................................................................................................................ 783 Starting Motor Dismounting and Remounting.............................................................................................................................................................................................................. 783 Starting Motor Components.............................................................................................................................................................................................................................. 784 Starting Motor Inspection.............................................................................................................................................................................................................................. 786 Specifications............................................................................................................................................................................................................................................. 789 Cranking System Specifications......................................................................................................................................................................................................................... 789 Tightening Torque Specifications....................................................................................................................................................................................................................... 790 Special Tools and Equipment................................................................................................................................................................................................................................ 790 Recommended Service Material........................................................................................................................................................................................................................... 790 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 791 General Description........................................................................................................................................................................................................................................ 791 Cranking System Description............................................................................................................................................................................................................................ 791 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 791 Cranking System Circuit Diagram........................................................................................................................................................................................................................ 791 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 792 Cranking System Symptom Diagnosis...................................................................................................................................................................................................................... 792 Repair Instructions........................................................................................................................................................................................................................................ 794 Starting Motor Removal and Installation................................................................................................................................................................................................................ 794 Starting Motor Components.............................................................................................................................................................................................................................. 795 Starting Motor Inspection.............................................................................................................................................................................................................................. 796 Specifications............................................................................................................................................................................................................................................. 799 Cranking System Specifications......................................................................................................................................................................................................................... 799 Tightening Torque Specifications....................................................................................................................................................................................................................... 799 Special Tools and Equipment................................................................................................................................................................................................................................ 799 Recommended Service Material........................................................................................................................................................................................................................... 799 Charging System.................................................................................................................................................................................................................................................... 800 M13A / M15A / M16A............................................................................................................................................................................................................................................. 800 General Description........................................................................................................................................................................................................................................ 800 Battery Description.................................................................................................................................................................................................................................... 800 Generator Description (For 75A Type)................................................................................................................................................................................................................... 801 Generator Description (For 80A Type)................................................................................................................................................................................................................... 802 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 803 Battery Inspection..................................................................................................................................................................................................................................... 803 Generator Symptom Diagnosis............................................................................................................................................................................................................................ 804 Generator Test (Undercharged Battery Check) (For 75A Type)............................................................................................................................................................................................. 804 Generator Test (Undercharged Battery Check) (For 80A Type)............................................................................................................................................................................................. 805 Generator Test (Overcharged Battery Check)............................................................................................................................................................................................................. 806 Repair Instructions........................................................................................................................................................................................................................................ 807 Jump Starting in Case of Emergency..................................................................................................................................................................................................................... 807 Battery Dismounting and Remounting..................................................................................................................................................................................................................... 807 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.................................................................................................................................................................................... 808 Water Pump / Generator Drive Belt Removal and Installation............................................................................................................................................................................................. 808 Generator Unit Components.............................................................................................................................................................................................................................. 809 Generator Dismounting and Remounting................................................................................................................................................................................................................... 809 Generator Components................................................................................................................................................................................................................................... 810 Generator Inspection................................................................................................................................................................................................................................... 810 Specifications............................................................................................................................................................................................................................................. 812 Charging System Specifications......................................................................................................................................................................................................................... 812 Tightening Torque Specifications....................................................................................................................................................................................................................... 812 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 813 General Description........................................................................................................................................................................................................................................ 813 Battery Description.................................................................................................................................................................................................................................... 813 Generator Description.................................................................................................................................................................................................................................. 814 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 815 Battery Inspection..................................................................................................................................................................................................................................... 815 Generator Symptom Diagnosis............................................................................................................................................................................................................................ 816 Generator Test (Undercharged Battery Check)............................................................................................................................................................................................................ 817 Generator Test (Overcharged Battery Check)............................................................................................................................................................................................................. 817 Repair Instructions........................................................................................................................................................................................................................................ 818 Jump Starting in Case of Emergency..................................................................................................................................................................................................................... 818 Battery Removal and Installation....................................................................................................................................................................................................................... 818 Generator Removal and Installation..................................................................................................................................................................................................................... 819 Specifications............................................................................................................................................................................................................................................. 819 Charging System Specifications......................................................................................................................................................................................................................... 819 Tightening Torque Specifications....................................................................................................................................................................................................................... 819 Exhaust System..................................................................................................................................................................................................................................................... 820 M13A / M15A / M16A............................................................................................................................................................................................................................................. 820 General Description........................................................................................................................................................................................................................................ 820 Exhaust System Description............................................................................................................................................................................................................................. 820 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 820 Exhaust System Check................................................................................................................................................................................................................................... 820 Repair Instructions........................................................................................................................................................................................................................................ 820 Exhaust System Components.............................................................................................................................................................................................................................. 820 Exhaust Manifold Removal and Installation.............................................................................................................................................................................................................. 823 Exhaust Pipe and Muffler Removal and Installation...................................................................................................................................................................................................... 825 Specifications............................................................................................................................................................................................................................................. 826 Tightening Torque Specifications....................................................................................................................................................................................................................... 826 D13A / Z13DTJ.................................................................................................................................................................................................................................................. 827 General Description........................................................................................................................................................................................................................................ 827 Exhaust System Description............................................................................................................................................................................................................................. 827 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 827 Exhaust System Check................................................................................................................................................................................................................................... 827 Repair Instructions........................................................................................................................................................................................................................................ 827 Exhaust System Components.............................................................................................................................................................................................................................. 827 Exhaust Manifold Components............................................................................................................................................................................................................................ 829 Exhaust Manifold Removal and Installation.............................................................................................................................................................................................................. 829 Exhaust Manifold Inspection............................................................................................................................................................................................................................ 830 Catalytic Converter Removal and Installation........................................................................................................................................................................................................... 830 DPF‚ Removal and Installation.......................................................................................................................................................................................................................... 831 Exhaust Pipe and Muffler Removal and Installation...................................................................................................................................................................................................... 831 Specifications............................................................................................................................................................................................................................................. 832 Tightening Torque Specifications....................................................................................................................................................................................................................... 832 Suspension............................................................................................................................................................................................................................................................. 833 Precautions........................................................................................................................................................................................................................................................ 835 Precautions.................................................................................................................................................................................................................................................... 835 Precautions on Suspension.................................................................................................................................................................................................................................. 835 Suspension General Diagnosis....................................................................................................................................................................................................................................... 836 Diagnostic Information and Procedures.......................................................................................................................................................................................................................... 836 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................................................. 836 Front Suspension................................................................................................................................................................................................................................................... 838 General Description............................................................................................................................................................................................................................................ 838 Front Suspension Construction (Other Than M16A Engine Model)............................................................................................................................................................................................... 838 Front Suspension Construction (M16A Engine Model).......................................................................................................................................................................................................... 839 Front Wheel Alignment Construction......................................................................................................................................................................................................................... 839 Repair Instructions............................................................................................................................................................................................................................................ 840 Front Wheel Alignment Inspection and Adjustment............................................................................................................................................................................................................ 840 Front Strut Assembly Components............................................................................................................................................................................................................................ 842 Front Strut Assembly Removal and Installation.............................................................................................................................................................................................................. 843 Front Strut Assembly Disassembly and Assembly.............................................................................................................................................................................................................. 845 Front Strut Assembly Check................................................................................................................................................................................................................................. 846 Front Wheel Hub and Steering Knuckle Components............................................................................................................................................................................................................ 847 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation............................................................................................................................................................................... 848 Front Wheel Hub, Disc, Nut and Bearing Check............................................................................................................................................................................................................... 851 Suspension Arm / Bush Removal and Installation............................................................................................................................................................................................................. 851 Suspension Arm Bush Disassembly and Assembly............................................................................................................................................................................................................... 852 Suspension Arm and Steering Knuckle Check.................................................................................................................................................................................................................. 853 Suspension Arm Bush Check.................................................................................................................................................................................................................................. 853 Suspension Arm Joint Check................................................................................................................................................................................................................................. 853 Front Suspension Frame, Stabilizer Bar and/or Bushes Components............................................................................................................................................................................................ 854 Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation................................................................................................................................................................................ 855 Front Suspension Frame Check............................................................................................................................................................................................................................... 858 Front Stabilizer Bar, Bush and/or Joint Check.............................................................................................................................................................................................................. 858 Front Suspension Fasteners Check........................................................................................................................................................................................................................... 858 Specifications................................................................................................................................................................................................................................................. 858 Tightening Torque Specifications........................................................................................................................................................................................................................... 858 Special Tools and Equipment.................................................................................................................................................................................................................................... 859 Special Tool............................................................................................................................................................................................................................................... 859 Rear Suspension.................................................................................................................................................................................................................................................... 861 General Description............................................................................................................................................................................................................................................ 861 Rear Suspension Construction (For Drum Brake Type)......................................................................................................................................................................................................... 861 Rear Suspension Construction (For Disc Brake Type)......................................................................................................................................................................................................... 862 Repair Instructions............................................................................................................................................................................................................................................ 863 Rear Wheel Alignment Inspection............................................................................................................................................................................................................................ 863 Rear Shock Absorber Removal and Installation............................................................................................................................................................................................................... 863 Rear Shock Absorber Inspection............................................................................................................................................................................................................................. 864 Rear Shock Absorber Bush Removal and Installation.......................................................................................................................................................................................................... 864 Rear Shock Absorber Bush Inspection........................................................................................................................................................................................................................ 864 Coil Spring Removal and Installation....................................................................................................................................................................................................................... 865 Spring Upper Seat / Spring Lower Seat Inspection........................................................................................................................................................................................................... 866 Spring Upper Seat and Lower Seat Removal and Installation.................................................................................................................................................................................................. 866 Rear Axle Removal and Installation (For Drum Brake Type)................................................................................................................................................................................................... 867 Rear Axle Removal and Installation (For Disc Brake Type)................................................................................................................................................................................................... 870 Trailing Arm, Rear Axle and Coil Spring Inspection......................................................................................................................................................................................................... 872 Rear Axle Bush Inspection.................................................................................................................................................................................................................................. 872 Wheel Bearing Removal and Installation (For Drum Brake Type)............................................................................................................................................................................................... 873 Rear Wheel Disc, Bolt and Bearing Inspection (For Drum Brake Type)......................................................................................................................................................................................... 874 Spindle Removal and Installation (For Drum Brake Type)..................................................................................................................................................................................................... 874 Spindle Inspection (For Drum Brake Type)................................................................................................................................................................................................................... 875 Rear Suspension Fasteners Inspection (For Drum Brake Type)................................................................................................................................................................................................. 875 Rear Wheel Hub Components (For Disc Brake Type)............................................................................................................................................................................................................ 876 Rear Wheel Hub Removal and Installation (For Disc Brake Type).............................................................................................................................................................................................. 877 Rear Wheel Disc, bolt and Bearing Inspection............................................................................................................................................................................................................... 878 Spindle Removal and Installation (For Disc Brake Type)..................................................................................................................................................................................................... 878 Spindle Inspection (For Disc Brake Type)................................................................................................................................................................................................................... 879 Rear Suspension Fasteners Inspection....................................................................................................................................................................................................................... 879 Specifications................................................................................................................................................................................................................................................. 879 Tightening Torque Specifications........................................................................................................................................................................................................................... 879 Special Tools and Equipment.................................................................................................................................................................................................................................... 880 Special Tool............................................................................................................................................................................................................................................... 880 Wheels and Tires................................................................................................................................................................................................................................................... 881 Precautions.................................................................................................................................................................................................................................................... 881 Precaution for Emergency Flat Tire Repair Kit.............................................................................................................................................................................................................. 881 General Description............................................................................................................................................................................................................................................ 881 Tires Description.......................................................................................................................................................................................................................................... 881 Wheels Description......................................................................................................................................................................................................................................... 882 Irregular and/or Premature Wear Description................................................................................................................................................................................................................ 883 Wear Indicators Description................................................................................................................................................................................................................................ 883 Radial Tire Waddle Description............................................................................................................................................................................................................................. 884 Radial Tire Lead / Pull Description........................................................................................................................................................................................................................ 885 Balancing Wheels Description............................................................................................................................................................................................................................... 885 Repair Instructions............................................................................................................................................................................................................................................ 885 General Balance Procedures................................................................................................................................................................................................................................. 885 Tire Rotation.............................................................................................................................................................................................................................................. 886 Wheel (with Tire) Removal and Installation................................................................................................................................................................................................................. 886 Tire Mounting and Dismounting.............................................................................................................................................................................................................................. 887 Tire Repair................................................................................................................................................................................................................................................ 887 Tire Repair for Emergency Repaired-Tire with Sealant....................................................................................................................................................................................................... 888 Specifications................................................................................................................................................................................................................................................. 889 Wheels and Tires Specifications............................................................................................................................................................................................................................ 889 Tightening Torque Specifications........................................................................................................................................................................................................................... 889 Driveline / Axle....................................................................................................................................................................................................................................................... 891 Precautions........................................................................................................................................................................................................................................................ 892 Precautions.................................................................................................................................................................................................................................................... 892 Precautions for Driveline / Axle........................................................................................................................................................................................................................... 892 Drive Shaft / Axle................................................................................................................................................................................................................................................. 893 General Description............................................................................................................................................................................................................................................ 893 Front Drive Shaft Construction............................................................................................................................................................................................................................. 893 Component Location............................................................................................................................................................................................................................................. 893 Front Drive Shaft Assembly Components Location............................................................................................................................................................................................................. 893 Diagnostic Information and Procedures.......................................................................................................................................................................................................................... 894 Front Drive Shaft Symptom Diagnosis........................................................................................................................................................................................................................ 894 Repair Instructions............................................................................................................................................................................................................................................ 895 Front Drive Shaft Components (M13A Engine and M15A Engine Models).......................................................................................................................................................................................... 895 Front Drive Shaft Components (M16A Engine and Z13DT Engine Models)......................................................................................................................................................................................... 896 Front Drive Shaft Assembly On-Vehicle Inspection........................................................................................................................................................................................................... 897 Front Drive Shaft Assembly Removal and Installation........................................................................................................................................................................................................ 897 Front Drive Shaft Disassembly and Assembly................................................................................................................................................................................................................. 899 Center Shaft and Center Bearing Support Disassembly and Assembly........................................................................................................................................................................................... 906 Front Drive Shaft Inspection............................................................................................................................................................................................................................... 909 Specifications................................................................................................................................................................................................................................................. 909 Tightening Torque Specifications........................................................................................................................................................................................................................... 909 Special Tools and Equipment.................................................................................................................................................................................................................................... 910 Recommended Service Material............................................................................................................................................................................................................................... 910 Special Tool............................................................................................................................................................................................................................................... 910 Brakes................................................................................................................................................................................................................................................................. 911 Precautions........................................................................................................................................................................................................................................................ 915 Precautions.................................................................................................................................................................................................................................................... 915 Precautions for Brakes..................................................................................................................................................................................................................................... 915 Brake Control System and Diagnosis................................................................................................................................................................................................................................. 916 Precautions.................................................................................................................................................................................................................................................... 916 Precautions on Brake....................................................................................................................................................................................................................................... 916 General Description............................................................................................................................................................................................................................................ 917 Brakes Construction........................................................................................................................................................................................................................................ 917 Front Brake Hose / Pipe Construction (Non-ESP‚ Model)...................................................................................................................................................................................................... 918 Front Brake Hose / Pipe Construction (ESP‚ Model).......................................................................................................................................................................................................... 919 Rear Brake Hose / Pipe Construction........................................................................................................................................................................................................................ 920 Diagnostic Information and Procedures.......................................................................................................................................................................................................................... 921 Brakes Diagnosis Note...................................................................................................................................................................................................................................... 921 Brakes Symptom Diagnosis................................................................................................................................................................................................................................... 921 Repair Instructions............................................................................................................................................................................................................................................ 924 Brake Pedal Free Height Inspection......................................................................................................................................................................................................................... 924 Brake Pedal Play Inspection................................................................................................................................................................................................................................ 924 Excessive Pedal Travel Inspection.......................................................................................................................................................................................................................... 925 Master Cylinder and Brake Fluid Level Inspection........................................................................................................................................................................................................... 925 Brake Light Switch Adjustment.............................................................................................................................................................................................................................. 926 Air Bleeding of Brake System............................................................................................................................................................................................................................... 926 Front Brake Hose / Pipe Removal and Installation........................................................................................................................................................................................................... 927 Rear Brake Hose / Pipe Removal and Installation............................................................................................................................................................................................................ 928 Brake Hose and Pipe Inspection............................................................................................................................................................................................................................. 928 Master Cylinder Components................................................................................................................................................................................................................................. 929 Master Cylinder Assembly Removal and Installation.......................................................................................................................................................................................................... 929 Master Cylinder Reservoir Removal and Installation......................................................................................................................................................................................................... 931 Master Cylinder Assembly Inspection........................................................................................................................................................................................................................ 932 Brake Booster Components................................................................................................................................................................................................................................... 932 Booster Operation Inspection............................................................................................................................................................................................................................... 933 Brake Booster Removal and Installation..................................................................................................................................................................................................................... 934 Brake Booster Inspection................................................................................................................................................................................................................................... 935 Specifications................................................................................................................................................................................................................................................. 936 Tightening Torque Specifications........................................................................................................................................................................................................................... 936 Special Tools and Equipment.................................................................................................................................................................................................................................... 936 Recommended Service Material............................................................................................................................................................................................................................... 936 Front Brakes....................................................................................................................................................................................................................................................... 937 Repair Instructions............................................................................................................................................................................................................................................ 937 Front Disc Brake Components................................................................................................................................................................................................................................ 937 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................................................. 938 Front Disc Brake Pad Removal and Installation.............................................................................................................................................................................................................. 938 Front Disc Brake Pad Inspection............................................................................................................................................................................................................................ 939 Front Disc Brake Caliper Removal and Installation.......................................................................................................................................................................................................... 939 Front Disc Brake Caliper Disassembly and Assembly.......................................................................................................................................................................................................... 940 Front Disc Brake Caliper Inspection........................................................................................................................................................................................................................ 942 Front Brake Disc Removal and Installation.................................................................................................................................................................................................................. 942 Front Brake Disc Inspection................................................................................................................................................................................................................................ 943 Specifications................................................................................................................................................................................................................................................. 944 Tightening Torque Specifications........................................................................................................................................................................................................................... 944 Special Tools and Equipment.................................................................................................................................................................................................................................... 944 Recommended Service Material............................................................................................................................................................................................................................... 944 Special Tool............................................................................................................................................................................................................................................... 944 Rear Brakes........................................................................................................................................................................................................................................................ 945 Drum Brake..................................................................................................................................................................................................................................................... 945 Repair Instructions........................................................................................................................................................................................................................................ 945 Rear Drum Brake Components............................................................................................................................................................................................................................. 945 Rear Brake Drum Removal and Installation............................................................................................................................................................................................................... 946 Rear Brake Drum and Shoe Inspection.................................................................................................................................................................................................................... 947 Rear Brake Shoe On-Vehicle Inspection.................................................................................................................................................................................................................. 948 Rear Brake Shoe Removal and Installation............................................................................................................................................................................................................... 948 Rear Brake Adjuster and Shoe Lever Inspection.......................................................................................................................................................................................................... 949 Wheel Cylinder Removal and Installation................................................................................................................................................................................................................ 949 Wheel Cylinder Inspection.............................................................................................................................................................................................................................. 950 Brake Back Plate Removal and Installation.............................................................................................................................................................................................................. 950 Specifications............................................................................................................................................................................................................................................. 951 Tightening Torque Specifications....................................................................................................................................................................................................................... 951 Special Tools and Equipment................................................................................................................................................................................................................................ 951 Recommended Service Material........................................................................................................................................................................................................................... 951 Special Tool........................................................................................................................................................................................................................................... 951 Disc Brake..................................................................................................................................................................................................................................................... 952 Repair Instructions........................................................................................................................................................................................................................................ 952 Rear Disc Brake Components............................................................................................................................................................................................................................. 952 Rear Disc Brake Pad Removal and Installation........................................................................................................................................................................................................... 953 Rear Disc Brake Caliper Removal and Installation....................................................................................................................................................................................................... 954 Rear Disc Brake Pad Inspection......................................................................................................................................................................................................................... 956 Rear Disc Brake Caliper Disassembly and Assembly....................................................................................................................................................................................................... 956 Rear Disc Brake Caliper Inspection..................................................................................................................................................................................................................... 958 Rear Brake Disc Removal and Installation............................................................................................................................................................................................................... 958 Rear Brake Disc Inspection............................................................................................................................................................................................................................. 959 Specifications............................................................................................................................................................................................................................................. 960 Tightening Torque Specifications....................................................................................................................................................................................................................... 960 Special Tools and Equipment................................................................................................................................................................................................................................ 960 Recommended Service Material........................................................................................................................................................................................................................... 960 Special Tool........................................................................................................................................................................................................................................... 960 Parking Brake...................................................................................................................................................................................................................................................... 961 General Description............................................................................................................................................................................................................................................ 961 Parking Brake Cable Construction (Other Than M16A Engine Model)............................................................................................................................................................................................ 961 Parking Brake Cable Construction (M16A Engine Model)....................................................................................................................................................................................................... 962 Repair Instructions............................................................................................................................................................................................................................................ 963 Parking Brake Inspection and Adjustment.................................................................................................................................................................................................................... 963 Parking Brake Cable Removal and Installation............................................................................................................................................................................................................... 964 Parking Brake Lever Removal and Installation............................................................................................................................................................................................................... 964 Specifications................................................................................................................................................................................................................................................. 965 Tightening Torque Specifications........................................................................................................................................................................................................................... 965 ABS................................................................................................................................................................................................................................................................ 966 Precautions.................................................................................................................................................................................................................................................... 966 Precautions in Diagnosing Troubles......................................................................................................................................................................................................................... 966 Precautions in On-Vehicle Service.......................................................................................................................................................................................................................... 966 Precautions in ABS Hydraulic Unit Operation Check.......................................................................................................................................................................................................... 966 General Description............................................................................................................................................................................................................................................ 967 ABS Description............................................................................................................................................................................................................................................ 967 ABS Hydraulic Unit / Control Module Assembly Description................................................................................................................................................................................................... 967 CAN Communication System Description....................................................................................................................................................................................................................... 968 Schematic and Routing Diagram.................................................................................................................................................................................................................................. 969 ABS Schematic.............................................................................................................................................................................................................................................. 969 ABS Wiring Circuit Diagram................................................................................................................................................................................................................................. 970 Component Location............................................................................................................................................................................................................................................. 972 ABS Component Location..................................................................................................................................................................................................................................... 972 Diagnostic Information and Procedures.......................................................................................................................................................................................................................... 973 ABS Check.................................................................................................................................................................................................................................................. 973 ABS Warning Light Check.................................................................................................................................................................................................................................... 975 EBD Warning Light (Brake Warning Light) Check.............................................................................................................................................................................................................. 975 DTC Check.................................................................................................................................................................................................................................................. 975 DTC Table.................................................................................................................................................................................................................................................. 976 Fail-Safe Control.......................................................................................................................................................................................................................................... 977 DTC Clearance.............................................................................................................................................................................................................................................. 978 Scan Tool Data............................................................................................................................................................................................................................................. 978 ABS Warning Light Does Not Come ON at Ignition Switch ON................................................................................................................................................................................................... 979 ABS Warning Light Comes ON Steady.......................................................................................................................................................................................................................... 980 EBD Warning Light (Brake Warning Light) Comes ON Steady.................................................................................................................................................................................................... 981 EBD Warning Light Does Not Come ON at Ignition Switch ON................................................................................................................................................................................................... 982 Serial Data Link Circuit Check............................................................................................................................................................................................................................. 982 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring................................................................................................ 984 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.................................. 986 DTC C1057: Power Source Circuit............................................................................................................................................................................................................................ 987 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit...................................................................................................................................................................................................... 989 DTC C1063: Solenoid Valve Power Supply Driver Circuit...................................................................................................................................................................................................... 990 DTC C1071: ABS Control Module.............................................................................................................................................................................................................................. 991 DTC U1073: Control Module Communication Bus Off............................................................................................................................................................................................................ 993 DTC U1100: Lost Communication with ECM (Reception Error)................................................................................................................................................................................................... 994 Repair Instructions............................................................................................................................................................................................................................................ 996 ABS Hydraulic Unit Operation Check......................................................................................................................................................................................................................... 996 ABS Hydraulic Unit / Control Module Assembly Components.................................................................................................................................................................................................... 997 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection......................................................................................................................................................................................... 997 ABS Hydraulic Unit / Control Module Assembly Removal and Installation...................................................................................................................................................................................... 997 Front Wheel Speed Sensor On-Vehicle Inspection............................................................................................................................................................................................................. 999 Front Wheel Speed Sensor Removal and Installation.......................................................................................................................................................................................................... 999 Front Wheel Speed Sensor Inspection........................................................................................................................................................................................................................1000 Rear Wheel Speed Sensor On-Vehicle Inspection..............................................................................................................................................................................................................1000 Rear Wheel Speed Sensor Removal and Installation...........................................................................................................................................................................................................1001 Rear Wheel Speed Sensor Inspection.........................................................................................................................................................................................................................1002 Front Wheel Speed Sensor Encoder Removal and Installation..................................................................................................................................................................................................1002 Rear Wheel Speed Sensor Ring Removal and Installation......................................................................................................................................................................................................1002 Front Wheel Speed Sensor Encoder and Rear Wheel Speed Sensor Ring Inspection...............................................................................................................................................................................1002 Specifications.................................................................................................................................................................................................................................................1003 Tightening Torque Specifications...........................................................................................................................................................................................................................1003 Special Tools and Equipment....................................................................................................................................................................................................................................1003 Special Tool...............................................................................................................................................................................................................................................1003 Electronic Stability Program.......................................................................................................................................................................................................................................1004 Precautions....................................................................................................................................................................................................................................................1004 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................1004 Precautions in On-Vehicle Service..........................................................................................................................................................................................................................1004 Precautions in ESP‚ Hydraulic Unit Operation Check.........................................................................................................................................................................................................1004 Precautions in Sensor Calibration..........................................................................................................................................................................................................................1004 Precautions in Speedometer Test or Other Tests.............................................................................................................................................................................................................1005 General Description............................................................................................................................................................................................................................................1005 Electronic Stability Program Description...................................................................................................................................................................................................................1005 ESP‚ Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................................................1006 Warning Light, Indicator Light Description.................................................................................................................................................................................................................1006 CAN Communication System Description.......................................................................................................................................................................................................................1007 CAN Communication System For Electronic Stability Program Description......................................................................................................................................................................................1008 Schematic and Routing Diagram..................................................................................................................................................................................................................................1009 ESP‚ Block Diagram.........................................................................................................................................................................................................................................1009 ESP‚ Circuit Diagram.......................................................................................................................................................................................................................................1010 Component Location.............................................................................................................................................................................................................................................1013 ESP‚ Component Location....................................................................................................................................................................................................................................1013 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1014 Electronic Stability Program Check.........................................................................................................................................................................................................................1014 ESP‚ Warning Light Check...................................................................................................................................................................................................................................1016 ABS Warning Light Check....................................................................................................................................................................................................................................1016 EBD Warning Light (Brake Warning Light) Check..............................................................................................................................................................................................................1017 DTC Check..................................................................................................................................................................................................................................................1017 DTC Table..................................................................................................................................................................................................................................................1017 DTC Clearance..............................................................................................................................................................................................................................................1021 Scan Tool Data.............................................................................................................................................................................................................................................1021 Visual Inspection..........................................................................................................................................................................................................................................1022 ESP‚ Warning Light Does Not Come ON at Ignition Switch ON..................................................................................................................................................................................................1023 ESP‚ Warning Light Comes ON Steady.........................................................................................................................................................................................................................1024 ABS Warning Light Does Not Come ON at Ignition Switch ON...................................................................................................................................................................................................1025 ABS Warning Light Comes ON Steady..........................................................................................................................................................................................................................1026 EBD Warning Light (Brake Warning Light) Comes ON Steady....................................................................................................................................................................................................1026 EBD Warning Light Does Not Come ON at Ignition Switch ON...................................................................................................................................................................................................1027 Serial Data Link Circuit Check.............................................................................................................................................................................................................................1028 DTC C1016: Brake Light Switch Circuit Failure..............................................................................................................................................................................................................1030 DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor in Yaw Rate / G Sensor Assembly Failure..............................................................................................................................................................1031 DTC C1018: Brake Fluid Level Switch Failure................................................................................................................................................................................................................1032 DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure.............................................................................................................................................................................................1033 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure............................................................................................1034 DTC C1024: Steering Angle Sensor Circuit Failure...........................................................................................................................................................................................................1036 DTC C1027: ESP‚ OFF Switch or TCSS OFF Switch Circuit Failure..............................................................................................................................................................................................1037 DTC C1028: Master Cylinder Pressure Sensor Circuit Failure.................................................................................................................................................................................................1038 DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure...............................................................................................................................................................................................1038 DTC C1037: Steering Angle Sensor Power Supply Failure......................................................................................................................................................................................................1040 DTC C1038: Steering Angle Sensor Detect Rolling Counter Failure from ESP‚ Control Module...................................................................................................................................................................1041 DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure...................................................................................................................................................................................................1042 DTC C1040: Stability Control Function Failure..............................................................................................................................................................................................................1042 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet Solenoid Circuit Failure, Outlet Solenoid Circuit Failure, Master Cylinder Cut Solenoid Circuit Failure, Low Pressure Solenoid Circuit Failure....1043 DTC C1057: ESP‚ Control Module Power Supply Circuit Failure................................................................................................................................................................................................1044 DTC C1061: Pump Motor and/or Motor Driver Circuit Failure..................................................................................................................................................................................................1045 DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure..............................................................................................................................................................................................1046 DTC 1071: ESP‚ Control Module Internal Defect..............................................................................................................................................................................................................1047 DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly............................................................................................................................................................................................1048 DTC C1075 / 1076 / 1078: Steering Angle Sensor / Master Cylinder Pressure Sensor / Lateral G Sensor in Yaw Rate / G Sensor Assembly Calibration Incomplete.................................................................................................1049 DTC C1090: ECM Detect Rolling Counter Failure from ESP‚ Control Module.....................................................................................................................................................................................1050 DTC C1091 / C1092 / C1094: ECM / TCM Data in CAN Line Failure / Torque Request Reject Status...............................................................................................................................................................1050 DTC U1073: Control Module Communication Bus Off............................................................................................................................................................................................................1051 DTC U1100: Lost Communication with ECM (Reception Error)...................................................................................................................................................................................................1052 DTC U1101: Lost Communication with TCM (Reception Error)...................................................................................................................................................................................................1053 DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error).................................................................................................................................................................................1055 DTC U1140: Lost Communication with BCM (Reception Error)...................................................................................................................................................................................................1056 Repair Instructions............................................................................................................................................................................................................................................1057 ESP‚ Hydraulic Unit Operation Check........................................................................................................................................................................................................................1057 Sensor Calibration.........................................................................................................................................................................................................................................1058 ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................................................1059 ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation.....................................................................................................................................................................................1059 Front / Rear Wheel Speed Sensor On-Vehicle Inspection......................................................................................................................................................................................................1061 Front Wheel Speed Sensor Removal and Installation..........................................................................................................................................................................................................1062 Front Wheel Speed Sensor Inspection........................................................................................................................................................................................................................1062 Rear Wheel Speed Sensor Removal and Installation...........................................................................................................................................................................................................1062 Rear Wheel Speed Sensor Inspection.........................................................................................................................................................................................................................1063 Front Wheel Speed Sensor Encoder On-Vehicle Inspection.....................................................................................................................................................................................................1063 Front Wheel Speed Sensor Encoder Removal and Installation..................................................................................................................................................................................................1063 Rear Wheel Speed Sensor Ring On-Vehicle Inspection.........................................................................................................................................................................................................1063 Rear Wheel Speed Sensor Ring Removal and Installation......................................................................................................................................................................................................1063 Master Cylinder Pressure Sensor On-Vehicle Inspection......................................................................................................................................................................................................1064 Yaw Rate / G Sensor Assembly On-Vehicle Inspection.........................................................................................................................................................................................................1064 Yaw Rate / G Sensor Assembly Removal and Installation......................................................................................................................................................................................................1066 Yaw Rate / G Sensor Inspection.............................................................................................................................................................................................................................1067 Steering Angle Sensor On-Vehicle Inspection................................................................................................................................................................................................................1067 Steering Angle Sensor Removal and Installation.............................................................................................................................................................................................................1067 Steering Angle Sensor Inspection...........................................................................................................................................................................................................................1067 ESP‚ OFF Switch or TCSS OFF Switch Removal and Installation................................................................................................................................................................................................1068 ESP‚ OFF Switch or TCSS OFF Switch Inspection..............................................................................................................................................................................................................1068 Specifications.................................................................................................................................................................................................................................................1068 Tightening Torque Specifications...........................................................................................................................................................................................................................1068 Special Tools and Equipment....................................................................................................................................................................................................................................1069 Special Tool...............................................................................................................................................................................................................................................1069 Transmission / Transaxle...............................................................................................................................................................................................................................................1071 Precautions........................................................................................................................................................................................................................................................1077 Precautions....................................................................................................................................................................................................................................................1077 Precautions on Transmission / Transaxle....................................................................................................................................................................................................................1077 Automatic Transmission/Transaxle...................................................................................................................................................................................................................................1078 Precautions....................................................................................................................................................................................................................................................1078 Precautions in Diagnosing Trouble..........................................................................................................................................................................................................................1078 Precautions for Disassembly and Reassembly.................................................................................................................................................................................................................1078 General Description............................................................................................................................................................................................................................................1080 A/T Description............................................................................................................................................................................................................................................1080 Clutch / Brake / Planetary Gear Function of Automatic Transaxle............................................................................................................................................................................................1083 Table of Component Operation...............................................................................................................................................................................................................................1084 A/T Diagnosis General Description..........................................................................................................................................................................................................................1084 On-Board Diagnostic System Description.....................................................................................................................................................................................................................1085 CAN Communication System Description.......................................................................................................................................................................................................................1086 Schematic and Routing Diagram..................................................................................................................................................................................................................................1087 Transmission Control Module (TCM) Wiring Diagram...........................................................................................................................................................................................................1087 Automatic Gear Shift Table.................................................................................................................................................................................................................................1089 Component Location.............................................................................................................................................................................................................................................1090 Electronic Shift Control System Components Location........................................................................................................................................................................................................1090 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1092 A/T System Check...........................................................................................................................................................................................................................................1092 Visual Inspection..........................................................................................................................................................................................................................................1095 Malfunction Indicator Lamp (MIL) Check.....................................................................................................................................................................................................................1095 DTC Table..................................................................................................................................................................................................................................................1096 DTC Check..................................................................................................................................................................................................................................................1098 DTC Clearance..............................................................................................................................................................................................................................................1098 Fail-Safe Table............................................................................................................................................................................................................................................1099 Scan Tool Data.............................................................................................................................................................................................................................................1101 A/T Basic Check............................................................................................................................................................................................................................................1104 Road Test..................................................................................................................................................................................................................................................1105 Manual Road Test...........................................................................................................................................................................................................................................1107 Engine Brake Test..........................................................................................................................................................................................................................................1108 Stall Test.................................................................................................................................................................................................................................................1108 Time Lag Test..............................................................................................................................................................................................................................................1109 Line Pressure Test.........................................................................................................................................................................................................................................1110 “P” Range Test.............................................................................................................................................................................................................................................1111 A/T Symptom Diagnosis......................................................................................................................................................................................................................................1111 No Gear Shift to 4th gear..................................................................................................................................................................................................................................1119 No Lock-Up Occurs..........................................................................................................................................................................................................................................1120 DTC P0602: Control Module Programming Error................................................................................................................................................................................................................1121 DTC P0705: Transmission Range Sensor Circuit Malfunction...................................................................................................................................................................................................1122 DTC P0707: Transmission Range Sensor Circuit Low...........................................................................................................................................................................................................1124 DTC P0711: Transmission Fluid Temperature Sensor “A” Circuit Range / Performance...........................................................................................................................................................................1126 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low...............................................................................................................................................................................................1127 DTC P0713: Transmission Fluid Temperature Sensor Circuit High..............................................................................................................................................................................................1128 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction................................................................................................................................................................................................1129 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal.....................................................................................................................................................................................................1131 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON.............................................................................................................................................................................1132 DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction..............................................................................................................................................................................................1133 DTC P0787: Shift / Timing Solenoid Control Circuit Low.....................................................................................................................................................................................................1135 DTC P0788: Shift / Timing Solenoid Control Circuit High....................................................................................................................................................................................................1137 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance...............................................................................................................................................................................1139 DTC P0962: Pressure Control Solenoid Control Circuit Low...................................................................................................................................................................................................1141 DTC P0963: Pressure Control Solenoid Control Circuit High..................................................................................................................................................................................................1143 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low...............................................................................................................................................1145 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High..................................................................................................................................................................1147 DTC P1702: Internal Control Module Memory Check Sum Error..................................................................................................................................................................................................1149 DTC P1703: Can Invalid Data - TCM..........................................................................................................................................................................................................................1149 DTC P1723: Range Select Switch Malfunction.................................................................................................................................................................................................................1150 DTC P1774: Control Module Communication Bus Off............................................................................................................................................................................................................1151 DTC P1777: TCM Lost Communication with ECM (Reception Error)...............................................................................................................................................................................................1156 DTC P1778: TCM Lost Communication with BCM (Reception Error)...............................................................................................................................................................................................1159 DTC P1878: Torque Converter Clutch Shudder.................................................................................................................................................................................................................1162 DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance.....................................................................................................................................................1163 DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High....................................................................................................................................................................1165 DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low.............................................................................................................................................................1167 Inspection of TCM and Its Circuits.........................................................................................................................................................................................................................1169 TCM Power and Ground Circuit Check.........................................................................................................................................................................................................................1173 Brake Interlock System Inspection..........................................................................................................................................................................................................................1174 Repair Instructions............................................................................................................................................................................................................................................1175 Learning Control Initialization............................................................................................................................................................................................................................1175 A/T Fluid Level Check......................................................................................................................................................................................................................................1175 A/T Fluid Change...........................................................................................................................................................................................................................................1176 Selector Lever Components..................................................................................................................................................................................................................................1177 Select Lever Assembly Installation.........................................................................................................................................................................................................................1177 Select Lever Knob Installation.............................................................................................................................................................................................................................1177 Selector Lever Inspection..................................................................................................................................................................................................................................1177 Select Cable Components....................................................................................................................................................................................................................................1178 Select Cable Removal and Installation......................................................................................................................................................................................................................1178 Select Cable Adjustment....................................................................................................................................................................................................................................1178 Transmission Range Sensor (Shift Switch) Inspection and Adjustment.........................................................................................................................................................................................1179 Output Shaft Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................................................1180 Output Shaft Speed Sensor (VSS) Inspection.................................................................................................................................................................................................................1180 Input Shaft Speed Sensor Removal and Installation..........................................................................................................................................................................................................1181 Input Shaft Speed Sensor Inspection........................................................................................................................................................................................................................1181 Transmission Fluid Temperature Sensor Removal and Installation.............................................................................................................................................................................................1181 Transmission Fluid Temperature Sensor Inspection...........................................................................................................................................................................................................1182 “3” Position Switch Inspection.............................................................................................................................................................................................................................1182 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation.................................................................................................................................................................1183 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection..............................................................................................................................................................................1184 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation....................................................................................................................................1186 Pressure Control Solenoid Valve Inspection.................................................................................................................................................................................................................1186 Transmission Control Module (TCM) Removal and Installation.................................................................................................................................................................................................1187 A/T Relay Inspection.......................................................................................................................................................................................................................................1188 Differential Side Oil Seal Replacement.....................................................................................................................................................................................................................1188 Shift Lock Solenoid Inspection.............................................................................................................................................................................................................................1189 Shift Lock Solenoid Replacement............................................................................................................................................................................................................................1189 Key Interlock Cable Removal and Installation...............................................................................................................................................................................................................1190 A/T Fluid Cooler Hoses Replacement.........................................................................................................................................................................................................................1191 Automatic Transaxle Unit Components........................................................................................................................................................................................................................1191 Automatic Transaxle Unit Dismounting and Remounting........................................................................................................................................................................................................1192 Automatic Transaxle Assembly Components....................................................................................................................................................................................................................1194 Automatic Transaxle Unit Disassembly.......................................................................................................................................................................................................................1195 Oil Pump Assembly Components...............................................................................................................................................................................................................................1207 Oil Pump Assembly Disassembly and Reassembly...............................................................................................................................................................................................................1207 Oil Pump Assembly Inspection...............................................................................................................................................................................................................................1208 Direct Clutch Assembly Components..........................................................................................................................................................................................................................1210 Direct Clutch Assembly Preliminary Check...................................................................................................................................................................................................................1210 Direct Clutch Assembly Disassembly and Reassembly..........................................................................................................................................................................................................1211 Direct Clutch Assembly Inspection..........................................................................................................................................................................................................................1213 Forward and Reverse Clutch Assembly Components.............................................................................................................................................................................................................1214 Forward and Reverse Clutch Assembly Preliminary Check......................................................................................................................................................................................................1215 Forward and Reverse Clutch Assembly Disassembly and Reassembly.............................................................................................................................................................................................1215 Forward and Reverse Clutch Assembly Inspection.............................................................................................................................................................................................................1219 2nd Brake Piston Assembly Components.......................................................................................................................................................................................................................1220 2nd Brake Piston Assembly Disassembly and Reassembly.......................................................................................................................................................................................................1220 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components..................................................................................................................................................................................1221 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly..................................................................................................................................................................1221 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection..................................................................................................................................................................................1223 Countershaft Assembly Components...........................................................................................................................................................................................................................1223 Countershaft Assembly Disassembly and Reassembly...........................................................................................................................................................................................................1224 Valve Body Assembly Components.............................................................................................................................................................................................................................1225 Valve Body Assembly Disassembly and Reassembly.............................................................................................................................................................................................................1225 Differential Assembly Components...........................................................................................................................................................................................................................1227 Differential Assembly Disassembly and Reassembly...........................................................................................................................................................................................................1227 Differential Assembly Inspection...........................................................................................................................................................................................................................1229 Torque Converter Housing Disassembly and Reassembly........................................................................................................................................................................................................1229 Transaxle Case Disassembly and Reassembly..................................................................................................................................................................................................................1232 Automatic Transaxle Unit Inspection and Adjustment.........................................................................................................................................................................................................1233 Automatic Transaxle Unit Assembly..........................................................................................................................................................................................................................1235 Specifications.................................................................................................................................................................................................................................................1252 Tightening Torque Specifications...........................................................................................................................................................................................................................1252 Special Tools and Equipment....................................................................................................................................................................................................................................1253 Recommended Service Material...............................................................................................................................................................................................................................1253 Special Tool...............................................................................................................................................................................................................................................1253 Manual Transmission/Transaxle......................................................................................................................................................................................................................................1256 M13A Model.....................................................................................................................................................................................................................................................1256 General Description........................................................................................................................................................................................................................................1256 Manual Transaxle Construction and Servicing............................................................................................................................................................................................................1256 Diagnostic Information and Procedures......................................................................................................................................................................................................................1258 Manual Transaxle Symptom Diagnosis.....................................................................................................................................................................................................................1258 Repair Instructions........................................................................................................................................................................................................................................1258 Manual Transaxle Oil Change............................................................................................................................................................................................................................1258 Differential Side Oil Seal Replacement.................................................................................................................................................................................................................1259 Gear Shift Control Lever and Cable Components..........................................................................................................................................................................................................1260 Gear Shift Control Lever and Cable Removal and Installation............................................................................................................................................................................................1261 Gear Select Control Cable Adjustment...................................................................................................................................................................................................................1261 Back Up Light Switch Removal and Installation..........................................................................................................................................................................................................1262 Back Up Light Switch Inspection........................................................................................................................................................................................................................1262 Manual Transaxle Unit Components.......................................................................................................................................................................................................................1263 Manual Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................................................1263 Gear Shift and Select Shaft Assembly Components........................................................................................................................................................................................................1265 Gear Shift and Select Shaft Assembly Removal and Installation..........................................................................................................................................................................................1266 Gear Shift and Select Shaft Disassembly and Assembly...................................................................................................................................................................................................1267 Manual Transaxle Assembly Components...................................................................................................................................................................................................................1268 Fifth Gear Disassembly and Assembly....................................................................................................................................................................................................................1269 Manual Transaxle Assembly Disassembly and Reassembly...................................................................................................................................................................................................1272 Transaxle Right Case Disassembly and Assembly..........................................................................................................................................................................................................1276 Transaxle Left Case Disassembly and Assembly...........................................................................................................................................................................................................1277 Input Shaft and Countershaft Components................................................................................................................................................................................................................1278 Input Shaft Assembly Disassembly and Reassembly........................................................................................................................................................................................................1279 Countershaft Assembly Disassembly and Reassembly.......................................................................................................................................................................................................1281 Synchronizer Parts Inspection..........................................................................................................................................................................................................................1284 Gear Shift Shaft Components............................................................................................................................................................................................................................1284 5th and Reverse Gear Shift Shafts Disassembly and Assembly.............................................................................................................................................................................................1285 Gear Shift Shaft and Fork Inspection...................................................................................................................................................................................................................1285 Differential Components................................................................................................................................................................................................................................1286 Differential Disassembly and Assembly..................................................................................................................................................................................................................1286 Specifications.............................................................................................................................................................................................................................................1288 Tightening Torque Specifications.......................................................................................................................................................................................................................1288 Special Tools and Equipment................................................................................................................................................................................................................................1288 Recommended Service Material...........................................................................................................................................................................................................................1288 Special Tool...........................................................................................................................................................................................................................................1289 M15A and M16A Model............................................................................................................................................................................................................................................1291 General Description........................................................................................................................................................................................................................................1291 Manual Transaxle Construction and Servicing............................................................................................................................................................................................................1291 Diagnostic Information and Procedures......................................................................................................................................................................................................................1293 Manual Transaxle Symptom Diagnosis.....................................................................................................................................................................................................................1293 Repair Instructions........................................................................................................................................................................................................................................1293 Manual Transaxle Oil Change............................................................................................................................................................................................................................1293 Differential Side Oil Seal Replacement.................................................................................................................................................................................................................1294 Gear Shift Control Lever and Cable Components..........................................................................................................................................................................................................1295 Gear Shift Control Lever and Cable Removal and Installation............................................................................................................................................................................................1296 Gear Select Control Cable Adjustment...................................................................................................................................................................................................................1297 Back Up Light Switch Removal and Installation..........................................................................................................................................................................................................1297 Back Up Light Switch Inspection........................................................................................................................................................................................................................1298 Manual Transaxle Unit Components.......................................................................................................................................................................................................................1298 Manual Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................................................1299 Gear Shift and Select Shaft Assembly Components........................................................................................................................................................................................................1301 Gear Shift and Select Shaft Assembly Removal and Installation..........................................................................................................................................................................................1301 Gear Shift and Select Shaft Disassembly and Assembly...................................................................................................................................................................................................1302 Manual Transaxle Assembly Components...................................................................................................................................................................................................................1303 Fifth Gear Disassembly and Assembly....................................................................................................................................................................................................................1304 Manual Transaxle Assembly Disassembly and Reassembly...................................................................................................................................................................................................1307 Transaxle Right Case Disassembly and Assembly..........................................................................................................................................................................................................1312 Transaxle Left Case Disassembly and Assembly...........................................................................................................................................................................................................1313 Input Shaft and Countershaft Components................................................................................................................................................................................................................1314 Input Shaft Assembly Disassembly and Reassembly........................................................................................................................................................................................................1315 Countershaft Assembly Disassembly and Reassembly.......................................................................................................................................................................................................1317 Synchronizer Parts Inspection..........................................................................................................................................................................................................................1320 Gear Shift Shaft Components............................................................................................................................................................................................................................1320 5th and Reverse Gear Shift Shafts Disassembly and Assembly.............................................................................................................................................................................................1321 Gear Shift Shaft and Fork Inspection...................................................................................................................................................................................................................1321 Differential Components................................................................................................................................................................................................................................1322 Differential Disassembly and Assembly..................................................................................................................................................................................................................1322 Specifications.............................................................................................................................................................................................................................................1324 Tightening Torque Specifications.......................................................................................................................................................................................................................1324 Special Tools and Equipment................................................................................................................................................................................................................................1324 Recommended Service Material...........................................................................................................................................................................................................................1324 Special Tool...........................................................................................................................................................................................................................................1325 D13A and Z13DTJ Model..........................................................................................................................................................................................................................................1327 General Description........................................................................................................................................................................................................................................1327 Manual Transaxle Construction..........................................................................................................................................................................................................................1327 Diagnostic Information and Procedures......................................................................................................................................................................................................................1330 Manual Transaxle Symptom Diagnosis.....................................................................................................................................................................................................................1330 Repair Instructions........................................................................................................................................................................................................................................1332 Manual Transaxle Oil Level Check.......................................................................................................................................................................................................................1332 Manual Transaxle Oil Change............................................................................................................................................................................................................................1332 Differential Side Oil Seal Replacement.................................................................................................................................................................................................................1332 Gear Shift Control Lever and Cable Components..........................................................................................................................................................................................................1334 Gear Shift Control Lever and Cable Removal and Installation............................................................................................................................................................................................1335 Gear Select Control Cable Adjustment...................................................................................................................................................................................................................1335 Back Up Light Switch Removal and Installation..........................................................................................................................................................................................................1336 Back Up Light Switch Inspection........................................................................................................................................................................................................................1336 Manual Transaxle Unit Components.......................................................................................................................................................................................................................1337 Manual Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................................................1337 Gear Shift and Select Shaft Assembly Components........................................................................................................................................................................................................1339 Gear Shift and Select Shaft Assembly Removal and Installation..........................................................................................................................................................................................1340 Gear Shift and Select Shaft Assembly Disassembly and Reassembly........................................................................................................................................................................................1341 Manual Transaxle Assembly Components...................................................................................................................................................................................................................1342 Fifth Gear Disassembly and Reassembly..................................................................................................................................................................................................................1343 Manual Transaxle Assembly Disassembly and Reassembly...................................................................................................................................................................................................1346 Transaxle Right Case Disassembly and Reassembly........................................................................................................................................................................................................1350 Transaxle Left Case Disassembly and Reassembly.........................................................................................................................................................................................................1351 Input Shaft and Countershaft Components................................................................................................................................................................................................................1353 Input Shaft Disassembly and Reassembly.................................................................................................................................................................................................................1354 Countershaft Disassembly and Reassembly................................................................................................................................................................................................................1356 Gear Shift Shaft Components............................................................................................................................................................................................................................1360 5th and Reverse Gear Shift Shafts Disassembly and Reassembly...........................................................................................................................................................................................1361 Gear Shift Shaft and Fork Inspection...................................................................................................................................................................................................................1361 Differential Components................................................................................................................................................................................................................................1362 Differential Disassembly and Reassembly................................................................................................................................................................................................................1362 Specifications.............................................................................................................................................................................................................................................1364 Tightening Torque Specifications.......................................................................................................................................................................................................................1364 Special Tools and Equipment................................................................................................................................................................................................................................1365 Recommended Service Material...........................................................................................................................................................................................................................1365 Special Tool...........................................................................................................................................................................................................................................1365 Clutch.............................................................................................................................................................................................................................................................1368 General Description............................................................................................................................................................................................................................................1368 Clutch Construction........................................................................................................................................................................................................................................1368 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1369 Clutch System Symptom Diagnosis............................................................................................................................................................................................................................1369 Repair Instructions............................................................................................................................................................................................................................................1370 Clutch Pedal Position (CPP) Switch Removal and Installation (Diesel Model).................................................................................................................................................................................1370 Clutch Pedal Position (CPP) Switch Inspection (Diesel Model)...............................................................................................................................................................................................1370 Clutch Pedal Inspection....................................................................................................................................................................................................................................1370 Clutch Fluid Level Inspection..............................................................................................................................................................................................................................1371 Air Bleeding of Clutch System (For Petrol Engine Model)....................................................................................................................................................................................................1372 Air Bleeding of Clutch System (For Diesel Model)...........................................................................................................................................................................................................1372 Clutch Fluid Pipe and Hose Components (For Petrol Engine Model)............................................................................................................................................................................................1373 Clutch Fluid Pipe and Hose Location (For Diesel Engine Model)..............................................................................................................................................................................................1373 Clutch Fluid Pipe Removal and Installation.................................................................................................................................................................................................................1374 Clutch Fluid Pipe Inspection...............................................................................................................................................................................................................................1374 Clutch Master Cylinder Removal and Installation............................................................................................................................................................................................................1375 Clutch Operating Cylinder Removal and Installation (For Petrol Engine Model)...............................................................................................................................................................................1375 Clutch Operating Cylinder Assembly Removal and Installation (For Diesel Engine Model)......................................................................................................................................................................1376 Clutch Operating Cylinder Assembly Inspection..............................................................................................................................................................................................................1376 Clutch Pedal and Clutch Pedal Bracket Components...........................................................................................................................................................................................................1377 Clutch Cover, Clutch Disc and Flywheel Components..........................................................................................................................................................................................................1378 Clutch Cover, Clutch Disc and Flywheel Removal and Installation............................................................................................................................................................................................1379 Clutch Cover, Clutch Disc and Flywheel Inspection..........................................................................................................................................................................................................1381 Clutch Release System Removal and Installation (For Petrol Engine Model)...................................................................................................................................................................................1382 Clutch Release System Inspection (For Petrol Engine Model).................................................................................................................................................................................................1384 Specifications.................................................................................................................................................................................................................................................1384 Tightening Torque Specifications...........................................................................................................................................................................................................................1384 Special Tools and Equipment....................................................................................................................................................................................................................................1385 Recommended Service Material...............................................................................................................................................................................................................................1385 Special Tool...............................................................................................................................................................................................................................................1385 Automated Manual Transaxle.........................................................................................................................................................................................................................................1386 Precautions....................................................................................................................................................................................................................................................1386 Precautions in Diagnosing Trouble..........................................................................................................................................................................................................................1386 General Description............................................................................................................................................................................................................................................1387 Automated Manual Transaxle Description.....................................................................................................................................................................................................................1387 Function of Automated Manual Transaxle Control System Component............................................................................................................................................................................................1389 Automatic Gear Shift Table.................................................................................................................................................................................................................................1390 Automated Manual Transaxle Diagnosis General Description...................................................................................................................................................................................................1391 On-Board Diagnostic System Description.....................................................................................................................................................................................................................1391 CAN Communication System Description.......................................................................................................................................................................................................................1392 Schematic and Routing Diagram..................................................................................................................................................................................................................................1393 TCM (Automated Manual Transaxle) Wiring Diagram............................................................................................................................................................................................................1393 Component Location.............................................................................................................................................................................................................................................1395 Electronic Shift Control System Components Location........................................................................................................................................................................................................1395 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1396 Automated Manual Transaxle System Check....................................................................................................................................................................................................................1396 Visual Inspection..........................................................................................................................................................................................................................................1398 Malfunction Indicator Lamp (MIL) Check.....................................................................................................................................................................................................................1399 Automated Manual Transaxle Warning Lamp Check..............................................................................................................................................................................................................1399 DTC Table..................................................................................................................................................................................................................................................1399 DTC Check..................................................................................................................................................................................................................................................1401 DTC Clearance..............................................................................................................................................................................................................................................1402 Fail-Safe Table............................................................................................................................................................................................................................................1402 Scan Tool Data.............................................................................................................................................................................................................................................1404 Automated Manual Transaxle Symptom Diagnosis...............................................................................................................................................................................................................1406 Automated Manual Transaxle Warning Lamp Does Not Come ON at Ignition Switch ON.............................................................................................................................................................................1410 Automated Manual Transaxle Warning Lamp Remains ON at Ignition Switch ON...................................................................................................................................................................................1412 Starting Motor Control Relay Circuit Check.................................................................................................................................................................................................................1413 DTC P0705: Transmission Range Sensor Circuit Malfunction...................................................................................................................................................................................................1415 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction................................................................................................................................................................................................1417 DTC P0722: Output Speed Sensor Circuit.....................................................................................................................................................................................................................1419 DTC P0727: Engine Speed Input Circuit......................................................................................................................................................................................................................1421 DTC P0807: Clutch Position Sensor Circuit Low..............................................................................................................................................................................................................1422 DTC P0808: Clutch Position Sensor Circuit High.............................................................................................................................................................................................................1423 DTC P0810: Clutch Position Control Error...................................................................................................................................................................................................................1425 DTC P0902 / P0903: Clutch Actuator Circuit Low / High......................................................................................................................................................................................................1427 DTC P0906: Gate Select Position Circuit Low................................................................................................................................................................................................................1429 DTC P0907: Gate Select Position Circuit High...............................................................................................................................................................................................................1430 DTC P0909: Gate Select Control Error.......................................................................................................................................................................................................................1432 DTC P0912 / P0913: Gate Select Actuator Circuit Low / High.................................................................................................................................................................................................1434 DTC P0916: Gear Shift Position Circuit Low.................................................................................................................................................................................................................1436 DTC P0917: Gear Shift Position Circuit High................................................................................................................................................................................................................1437 DTC P0919: Gear Shift Position Control Error...............................................................................................................................................................................................................1439 DTC P1703: CAN Invalid Data - Automated Manual Transaxle Control...........................................................................................................................................................................................1441 DTC P1774: Control Module Communication Bus Off............................................................................................................................................................................................................1442 DTC P1777: TCM (Automated Manual Transaxle) Lost Communication with ECM (Reception Error)..................................................................................................................................................................1445 DTC P1778: TCM (Automated Manual Transaxle) Lost Communication with BCM (Reception Error)..................................................................................................................................................................1447 DTC P1840: TCM (Automated Manual Transaxle) System Voltage.................................................................................................................................................................................................1449 DTC P1841 / P1842: CPU Malfunction / TCM (Automated Manual Transaxle) Internal Module Keep Alive Memory Error..............................................................................................................................................1450 DTC P1843: Brake Switch “A/B” Error........................................................................................................................................................................................................................1450 DTC P1845: Warning Buzzer Circuit Malfunction..............................................................................................................................................................................................................1452 DTC P1846: Reverse Input Circuit No Signal.................................................................................................................................................................................................................1452 DTC P1847: Reverse Input Circuit Short.....................................................................................................................................................................................................................1454 DTC P1848: Motor Relay Circuit Low.........................................................................................................................................................................................................................1455 DTC P1849: Motor Relay Circuit High........................................................................................................................................................................................................................1457 DTC P1856: Clutch Position Sensor Circuit “B” Low..........................................................................................................................................................................................................1458 DTC P1857: Clutch Position Sensor Circuit “B” High.........................................................................................................................................................................................................1459 DTC P1858: Gate Select Position Circuit “B” Low............................................................................................................................................................................................................1461 DTC P1859: Gate Select Position Circuit “B” High...........................................................................................................................................................................................................1462 DTC P1880 / P1881: Gear Shift Actuator Circuit Low / High..................................................................................................................................................................................................1464 DTC P1882: Gear Shift Position Circuit “B” Low.............................................................................................................................................................................................................1466 DTC P1883: Gear Shift Position Circuit “B” High............................................................................................................................................................................................................1467 DTC P1900: Clutch Position Sensor “A/B” Correlation........................................................................................................................................................................................................1469 DTC P1901: Gear Shift Position Sensor “A/B” Correlation....................................................................................................................................................................................................1470 DTC P1960: Gate Select Position Sensor “A/B” Correlation...................................................................................................................................................................................................1471 TCM (Automated Manual Transaxle) Power and Ground Circuit Check............................................................................................................................................................................................1472 Inspection of TCM (Automated Manual Transaxle) and Its Circuits............................................................................................................................................................................................1473 Repair Instructions............................................................................................................................................................................................................................................1481 TCM (Automated Manual Transaxle) Initialization............................................................................................................................................................................................................1481 Clutch Position Control....................................................................................................................................................................................................................................1481 Automated Manual Transaxle Oil Change......................................................................................................................................................................................................................1481 Differential Side Oil Seal Replacement.....................................................................................................................................................................................................................1482 Shift Selector Components..................................................................................................................................................................................................................................1483 Shift Selector Assembly Removal and Installation...........................................................................................................................................................................................................1483 Shift Selector Assembly Disassembly and Reassembly.........................................................................................................................................................................................................1484 Shift Selector Inspection..................................................................................................................................................................................................................................1486 Clutch Stroke Sensor Removal and Installation..............................................................................................................................................................................................................1488 Clutch Stroke Sensor Inspection............................................................................................................................................................................................................................1488 Clutch Actuator Removal and Installation...................................................................................................................................................................................................................1489 Clutch Actuator Inspection.................................................................................................................................................................................................................................1490 Shift and Select Stroke Sensor Removal and Installation....................................................................................................................................................................................................1490 Shift Stroke Sensor and Select Stroke Sensor Inspection....................................................................................................................................................................................................1491 Shift and Select Actuator Removal and Installation.........................................................................................................................................................................................................1492 Shift and Select Actuator Inspection.......................................................................................................................................................................................................................1493 Input Shaft Speed Sensor Removal and Installation..........................................................................................................................................................................................................1493 Input Shaft Speed Sensor Inspection........................................................................................................................................................................................................................1494 Neutral Start Switch Removal and Installation..............................................................................................................................................................................................................1494 Neutral Start Switch Inspection............................................................................................................................................................................................................................1495 Back Up Lamp Switch Removal and Installation...............................................................................................................................................................................................................1495 Back Up Lamp Switch Inspection.............................................................................................................................................................................................................................1495 Output Shaft Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................................................1495 Transmission Control Module (TCM) Removal and Installation.................................................................................................................................................................................................1496 Motor Relay Inspection.....................................................................................................................................................................................................................................1496 Automated Manual Transaxle Unit Components.................................................................................................................................................................................................................1497 Automated Manual Transaxle Unit Dismounting and Remounting.................................................................................................................................................................................................1497 Automated Manual Transaxle Assembly Components.............................................................................................................................................................................................................1499 Automated Manual Transaxle Assembly Disassembly and Reassembly.............................................................................................................................................................................................1500 Left Case Assembly Disassembly and Reassembly..............................................................................................................................................................................................................1502 Countershaft Tapered Roller Bearing Preload Adjustment.....................................................................................................................................................................................................1504 Input Shaft Bearing Shim Adjustment........................................................................................................................................................................................................................1505 Differential Left Side Bearing Preload Adjustment..........................................................................................................................................................................................................1506 Right Case Assembly Disassembly and Reassembly.............................................................................................................................................................................................................1506 Input Shaft Assembly Components............................................................................................................................................................................................................................1508 Input Shaft Assembly Disassembly and Reassembly............................................................................................................................................................................................................1509 Input Shaft Assembly Inspection............................................................................................................................................................................................................................1512 Countershaft Components....................................................................................................................................................................................................................................1514 Countershaft Assembly Disassembly and Reassembly...........................................................................................................................................................................................................1515 Countershaft Assembly Inspection...........................................................................................................................................................................................................................1518 Gear Shift Shaft Components................................................................................................................................................................................................................................1519 Gear Shift Shaft Disassembly and Reassembly................................................................................................................................................................................................................1520 Gear Shift Shaft Inspection................................................................................................................................................................................................................................1521 Differential Components....................................................................................................................................................................................................................................1522 Differential Assembly Disassembly and Reassembly...........................................................................................................................................................................................................1522 Clutch Cover and Clutch Disc Components....................................................................................................................................................................................................................1524 Clutch Cover and Clutch Disc Removal and Installation......................................................................................................................................................................................................1525 Clutch Release System Component Removal and Installation...................................................................................................................................................................................................1525 Clutch Inspection..........................................................................................................................................................................................................................................1526 Specifications.................................................................................................................................................................................................................................................1527 Tightening Torque Specifications...........................................................................................................................................................................................................................1527 Special Tools and Equipment....................................................................................................................................................................................................................................1528 Recommended Service Material...............................................................................................................................................................................................................................1528 Special Tool...............................................................................................................................................................................................................................................1528 Steering...............................................................................................................................................................................................................................................................1531 Precautions........................................................................................................................................................................................................................................................1533 Precautions....................................................................................................................................................................................................................................................1533 Precautions on Steering....................................................................................................................................................................................................................................1533 Steering General Diagnosis.........................................................................................................................................................................................................................................1534 Precautions....................................................................................................................................................................................................................................................1534 Precautions for Steering Diagnosis.........................................................................................................................................................................................................................1534 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1534 Steering Symptom Diagnosis.................................................................................................................................................................................................................................1534 Steering Wheel and Column..........................................................................................................................................................................................................................................1536 Precautions....................................................................................................................................................................................................................................................1536 Service Precautions of Steering Wheel and Column...........................................................................................................................................................................................................1536 General Description............................................................................................................................................................................................................................................1536 Steering Wheel and Column Construction.....................................................................................................................................................................................................................1536 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1537 Checking Steering Column for Accident Damage...............................................................................................................................................................................................................1537 Repair Instructions............................................................................................................................................................................................................................................1538 Steering Wheel and Column Components.......................................................................................................................................................................................................................1538 Steering Wheel Removal and Installation....................................................................................................................................................................................................................1539 Contact Coil Cable Assembly Removal and Installation.......................................................................................................................................................................................................1540 Centering Contact Coil Cable Assembly......................................................................................................................................................................................................................1541 Contact Coil Cable Assembly Inspection.....................................................................................................................................................................................................................1541 Steering Angle Sensor Removal and Installation.............................................................................................................................................................................................................1541 Steering Angle Sensor Inspection...........................................................................................................................................................................................................................1542 Steering Column Removal and Installation...................................................................................................................................................................................................................1542 Steering Column Inspection.................................................................................................................................................................................................................................1544 Steering Lock Assembly (Ignition Switch) Removal and Installation..........................................................................................................................................................................................1544 Steering Lower Shaft Removal and Installation..............................................................................................................................................................................................................1545 Specifications.................................................................................................................................................................................................................................................1545 Tightening Torque Specifications...........................................................................................................................................................................................................................1545 Special Tools and Equipment....................................................................................................................................................................................................................................1546 Special Tool...............................................................................................................................................................................................................................................1546 Power Assisted Steering System.....................................................................................................................................................................................................................................1547 Precautions....................................................................................................................................................................................................................................................1547 Steering System Note.......................................................................................................................................................................................................................................1547 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................1547 General Description............................................................................................................................................................................................................................................1548 P/S System Description.....................................................................................................................................................................................................................................1548 EPS Diagnosis General Description..........................................................................................................................................................................................................................1549 On-Board Diagnostic System Description.....................................................................................................................................................................................................................1549 Schematic and Routing Diagram..................................................................................................................................................................................................................................1550 EPS System Wiring Circuit Diagram..........................................................................................................................................................................................................................1550 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1551 EPS System Check...........................................................................................................................................................................................................................................1551 “EPS” Warning Lamp Check...................................................................................................................................................................................................................................1554 DTC Check..................................................................................................................................................................................................................................................1554 DTC Clearance..............................................................................................................................................................................................................................................1554 DTC Table..................................................................................................................................................................................................................................................1555 Scan Tool Data.............................................................................................................................................................................................................................................1557 P/S System Symptom Diagnosis...............................................................................................................................................................................................................................1558 Serial Data Link Circuit Check.............................................................................................................................................................................................................................1558 “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stops.................................................................................................................................................................................1560 “EPS” Warning Lamp Comes ON Steady and Engine Start........................................................................................................................................................................................................1561 DTC C1113 / C1117 / C1118: Torque Sensor Circuit Failure...................................................................................................................................................................................................1562 DTC C1114: Steering Torque Sensor Reference Power Supply Circuit...........................................................................................................................................................................................1563 DTC C1119: Steering Torque Sensor Power Supply Circuit.....................................................................................................................................................................................................1565 DTC C1121 / C1123 / C1124: VSS Circuit Failure (For Petrol Engine Models)..................................................................................................................................................................................1566 DTC C1121 / C1123 / C1124: VSS Circuit Failure (For Diesel Engine Model)...................................................................................................................................................................................1567 DTC C1122: Engine Speed Signal.............................................................................................................................................................................................................................1569 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure...................................................................................................................................................................................................1570 DTC C1153: P/S Control Module Power Supply Circuit Failure.................................................................................................................................................................................................1571 DTC C1155: P/S Control Module Internal Failure.............................................................................................................................................................................................................1573 Inspection of P/S Control Module and Its Circuits..........................................................................................................................................................................................................1573 Steering Wheel Play Check..................................................................................................................................................................................................................................1578 Steering Force Check.......................................................................................................................................................................................................................................1578 Repair Instructions............................................................................................................................................................................................................................................1579 Steering Gear Case Assembly Components.....................................................................................................................................................................................................................1579 Tie-Rod End Boot On-Vehicle Inspection.....................................................................................................................................................................................................................1581 Tie-Rod End Removal and Installation.......................................................................................................................................................................................................................1581 Tie-Rod End Inspection.....................................................................................................................................................................................................................................1582 Steering Shaft Joint On-Vehicle Inspection.................................................................................................................................................................................................................1582 Steering Gear Case Assembly Removal and Installation.......................................................................................................................................................................................................1583 Steering Rack Boot Inspection..............................................................................................................................................................................................................................1584 Tie-Rod / Rack Boot Removal and Installation...............................................................................................................................................................................................................1584 Steering Rack Plunger Removal and Installation.............................................................................................................................................................................................................1585 Steering Rack Plunger Inspection...........................................................................................................................................................................................................................1586 P/S Control Module Removal and Installation................................................................................................................................................................................................................1586 Torque Sensor Inspection...................................................................................................................................................................................................................................1586 Motor Assembly Inspection..................................................................................................................................................................................................................................1587 Specifications.................................................................................................................................................................................................................................................1588 Tightening Torque Specifications...........................................................................................................................................................................................................................1588 Special Tools and Equipment....................................................................................................................................................................................................................................1589 Recommended Service Material...............................................................................................................................................................................................................................1589 Special Tool...............................................................................................................................................................................................................................................1589 HVAC...................................................................................................................................................................................................................................................................1591 Precautions........................................................................................................................................................................................................................................................1594 Precautions....................................................................................................................................................................................................................................................1594 Precautions on HVAC........................................................................................................................................................................................................................................1594 Heater and Ventilation.............................................................................................................................................................................................................................................1595 General Description............................................................................................................................................................................................................................................1595 Heater and Ventilation Construction........................................................................................................................................................................................................................1595 Additional Heater System Description (If Equipped).........................................................................................................................................................................................................1596 On-Board Diagnostic System Description (Additional Heater).................................................................................................................................................................................................1596 Schematic and Routing Diagram..................................................................................................................................................................................................................................1597 Additional Heater System Electronic Input / Output Diagram (If Equipped)...................................................................................................................................................................................1597 Heater and Ventilation Wiring Circuit Diagram (Petrol Engine Model)........................................................................................................................................................................................1597 Heater and Ventilation Wiring Circuit Diagram (Diesel Engine Model)........................................................................................................................................................................................1598 Component Location.............................................................................................................................................................................................................................................1599 Additional Heater System Components Location (If Equipped).................................................................................................................................................................................................1599 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1599 Heater and Ventilation Symptom Diagnosis...................................................................................................................................................................................................................1599 DTC Check (Additional Heater)..............................................................................................................................................................................................................................1600 DTC Clearance (Additional Heater)..........................................................................................................................................................................................................................1601 DTC Table (Additional Heater)..............................................................................................................................................................................................................................1601 Scan Tool Data (Additional Heater).........................................................................................................................................................................................................................1601 DTC B1536: Additional Heater Relay No.1 Output Malfunction.................................................................................................................................................................................................1602 DTC B1537: Additional Heater Relay No.2 and No.3 Output Malfunction........................................................................................................................................................................................1603 DTC B1541: Additional Heater Controller Back-Up Power Supply Malfunction...................................................................................................................................................................................1604 DTC B1551: Serial Communication Circuit Malfunction........................................................................................................................................................................................................1604 DTC B1552: Serial Communication Data Malfunction...........................................................................................................................................................................................................1605 DTC B1553: CAN Communication Circuit Malfunction...........................................................................................................................................................................................................1606 DTC B1556: Engine Speed Data Malfunction...................................................................................................................................................................................................................1606 DTC B1557: Vehicle Speed Data Malfunction..................................................................................................................................................................................................................1607 DTC B1559: Ignition Power Supply Voltage Data Malfunction..................................................................................................................................................................................................1607 DTC B1561: Engine Coolant Temperature Data Malfunction.....................................................................................................................................................................................................1607 DTC B1562: Outside Air Temperature Data Malfunction........................................................................................................................................................................................................1607 Inspection of Additional Heater Controller and Its Circuit (If Equipped)...................................................................................................................................................................................1608 Repair Instructions............................................................................................................................................................................................................................................1610 HVAC Unit Components.......................................................................................................................................................................................................................................1610 HVAC Unit Removal and Installation.........................................................................................................................................................................................................................1611 Blower Motor Removal and Installation......................................................................................................................................................................................................................1611 Blower Motor Inspection....................................................................................................................................................................................................................................1611 Blower Motor Resistor Removal and Installation.............................................................................................................................................................................................................1612 Blower Motor Resistor Inspection...........................................................................................................................................................................................................................1612 Blower Motor Relay and Additional Heater Relay (If Equipped) Inspection....................................................................................................................................................................................1613 Additional Heater Assembly On-Vehicle Inspection (If Equipped).............................................................................................................................................................................................1613 Additional Heater Assembly Removal and Installation (If Equipped)..........................................................................................................................................................................................1614 Additional Heater Controller Removal and Installation (If Equipped)........................................................................................................................................................................................1615 HVAC Control Unit Components...............................................................................................................................................................................................................................1615 HVAC Control Unit Removal and Installation.................................................................................................................................................................................................................1615 Blower Speed Selector Inspection...........................................................................................................................................................................................................................1617 Air Intake Selector Inspection.............................................................................................................................................................................................................................1617 Air Intake Control Actuator Removal and Installation.......................................................................................................................................................................................................1618 Air Intake Control Actuator Inspection.....................................................................................................................................................................................................................1618 Center Ventilation Louver Removal and Installation.........................................................................................................................................................................................................1619 Side Ventilation Louver Removal and Installation...........................................................................................................................................................................................................1619 Air Filter (If Equipped) Removal and Installation..........................................................................................................................................................................................................1620 Air Filter Cleaning (If Equipped)..........................................................................................................................................................................................................................1620 Specifications.................................................................................................................................................................................................................................................1621 Tightening Torque Specifications...........................................................................................................................................................................................................................1621 Special Tools and Equipment....................................................................................................................................................................................................................................1621 Special Tool...............................................................................................................................................................................................................................................1621 Air Conditioning System............................................................................................................................................................................................................................................1622 Manual A/C.....................................................................................................................................................................................................................................................1622 Precautions................................................................................................................................................................................................................................................1622 A/C System Caution.....................................................................................................................................................................................................................................1622 Precautions on Servicing A/C System....................................................................................................................................................................................................................1622 General Description........................................................................................................................................................................................................................................1624 Refrigerant Type Identification........................................................................................................................................................................................................................1624 Sub-Cool A/C System Description........................................................................................................................................................................................................................1625 A/C Operation Description..............................................................................................................................................................................................................................1626 Schematic and Routing Diagram..............................................................................................................................................................................................................................1626 Air Flow Diagram of A/C System.........................................................................................................................................................................................................................1626 A/C System Wiring Diagram (Petrol Engine Model)........................................................................................................................................................................................................1627 A/C System Wiring Diagram (Diesel Engine Model)........................................................................................................................................................................................................1628 Component Location.........................................................................................................................................................................................................................................1629 Major Components of A/C System.........................................................................................................................................................................................................................1629 Diagnostic Information and Procedures......................................................................................................................................................................................................................1630 A/C System Symptom Diagnosis...........................................................................................................................................................................................................................1630 Abnormal Noise Symptom Diagnosis of A/C System.........................................................................................................................................................................................................1632 A/C System Performance Inspection......................................................................................................................................................................................................................1634 A/C System Inspection at ECM...........................................................................................................................................................................................................................1638 Repair Instructions........................................................................................................................................................................................................................................1640 Operation Procedure for Refrigerant Charge.............................................................................................................................................................................................................1640 Condenser Assembly On-Vehicle Inspection...............................................................................................................................................................................................................1646 Condenser Assembly Removal and Installation............................................................................................................................................................................................................1646 Receiver/Dryer Removal and Installation................................................................................................................................................................................................................1647 HVAC Unit Components...................................................................................................................................................................................................................................1648 HVAC Unit Removal and Installation.....................................................................................................................................................................................................................1649 Evaporator Inspection..................................................................................................................................................................................................................................1649 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation.........................................................................................................................................................................1650 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection.......................................................................................................................................................................................1650 Expansion Valve Removal and Installation...............................................................................................................................................................................................................1651 Expansion Valve Inspection.............................................................................................................................................................................................................................1651 A/C Refrigerant Pressure Sensor and Its Circuit Inspection.............................................................................................................................................................................................1651 A/C Refrigerant Pressure Sensor Removal and Installation...............................................................................................................................................................................................1651 A/C Switch Inspection..................................................................................................................................................................................................................................1652 Compressor Relay Inspection............................................................................................................................................................................................................................1652 Compressor Drive Belt Inspection and Adjustment (Petrol Engine Model)..................................................................................................................................................................................1652 Compressor Drive Belt Inspection and Adjustment (Diesel Engine Model)..................................................................................................................................................................................1653 Compressor Drive Belt Removal and Installation (Petrol Engine Model)...................................................................................................................................................................................1653 Compressor Drive Belt Removal and Installation (Diesel Engine Model)...................................................................................................................................................................................1653 Compressor Assembly Removal and Installation (Petrol Engine Model).....................................................................................................................................................................................1653 Compressor Assembly Removal and Installation (Diesel Engine Model).....................................................................................................................................................................................1654 Compressor Assembly Components.........................................................................................................................................................................................................................1655 Magnet Clutch Inspection (Petrol Engine Model).........................................................................................................................................................................................................1655 Magnet Clutch Inspection (Diesel Engine Model).........................................................................................................................................................................................................1656 Magnet Clutch Removal and Installation.................................................................................................................................................................................................................1656 Thermal Switch Inspection..............................................................................................................................................................................................................................1657 Thermal Switch Removal and Installation................................................................................................................................................................................................................1657 Relief Valve Inspection (Petrol Engine Model)..........................................................................................................................................................................................................1658 Relief Valve Inspection (Diesel Engine Model)..........................................................................................................................................................................................................1658 Relief valve Removal and Installation..................................................................................................................................................................................................................1658 Specifications.............................................................................................................................................................................................................................................1659 Tightening Torque Specifications.......................................................................................................................................................................................................................1659 Special Tools and Equipment................................................................................................................................................................................................................................1659 Recommended Service Material...........................................................................................................................................................................................................................1659 Special Tool...........................................................................................................................................................................................................................................1659 Auto A/C.......................................................................................................................................................................................................................................................1660 Precautions................................................................................................................................................................................................................................................1660 A/C System Caution.....................................................................................................................................................................................................................................1660 Precautions in Diagnosing Trouble......................................................................................................................................................................................................................1660 Precautions on Servicing A/C System....................................................................................................................................................................................................................1660 General Description........................................................................................................................................................................................................................................1660 Auto A/C System Description............................................................................................................................................................................................................................1660 HVAC Control Module Operation Description..............................................................................................................................................................................................................1661 Refrigerant Type Identification........................................................................................................................................................................................................................1661 Sub-Cool A/C System Description........................................................................................................................................................................................................................1661 A/C Operation Description..............................................................................................................................................................................................................................1661 On-Board Diagnostic System Description.................................................................................................................................................................................................................1661 Schematic and Routing Diagram..............................................................................................................................................................................................................................1662 Air Flow Diagram of A/C System.........................................................................................................................................................................................................................1662 Auto A/C Electronic Control Input / Output Diagram.....................................................................................................................................................................................................1662 A/C System Wiring Diagram..............................................................................................................................................................................................................................1663 Component Location.........................................................................................................................................................................................................................................1664 Major Components of A/C System.........................................................................................................................................................................................................................1664 Electronic Control System Location.....................................................................................................................................................................................................................1664 Diagnostic Information and Procedures......................................................................................................................................................................................................................1665 A/C System Symptom Diagnosis...........................................................................................................................................................................................................................1665 Abnormal Noise Symptom Diagnosis of A/C System.........................................................................................................................................................................................................1668 DTC Check..............................................................................................................................................................................................................................................1668 DTC Clearance..........................................................................................................................................................................................................................................1670 DTC Table..............................................................................................................................................................................................................................................1671 Fail-Safe Table........................................................................................................................................................................................................................................1672 Scan Tool Data.........................................................................................................................................................................................................................................1672 Air Conditioning System Check..........................................................................................................................................................................................................................1674 Visual Inspection......................................................................................................................................................................................................................................1676 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction................................................................................................................................................................................1676 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction........................................................................................................................................................................1678 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction...............................................................................................................................................................................................1679 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction...............................................................................................................................................................1681 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction..................................................................................................................................................................1683 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction.................................................................................................................................................................................1685 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction....................................................................................................................................................................................1687 DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction........................................................................................................................................................................................1689 DTC B1546: A/C Refrigerant Pressure Malfunction........................................................................................................................................................................................................1690 DTC B1551: Serial Communication Circuit Malfunction....................................................................................................................................................................................................1691 DTC B1552: Serial Communication Signal Malfunction.....................................................................................................................................................................................................1692 DTC B1553: CAN Communication Signal Malfunction........................................................................................................................................................................................................1693 DTC B1557: Vehicle Speed Sensor Signal Malfunction.....................................................................................................................................................................................................1693 DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction........................................................................................................................................................................................1693 DTC B1562: Outside Air Temperature Sensor Signal Malfunction...........................................................................................................................................................................................1694 DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction..........................................................................................................................................................................................1694 Inspection of HVAC Control Module and Its Circuit......................................................................................................................................................................................................1695 A/C System Performance Inspection......................................................................................................................................................................................................................1697 A/C System Inspection at ECM...........................................................................................................................................................................................................................1697 Repair Instructions........................................................................................................................................................................................................................................1697 Operation Procedure for Refrigerant Charge.............................................................................................................................................................................................................1697 HVAC Unit Components...................................................................................................................................................................................................................................1698 HVAC Unit Removal and Installation.....................................................................................................................................................................................................................1699 Temperature Control Actuator Removal and Installation..................................................................................................................................................................................................1699 Temperature Control Actuator Inspection................................................................................................................................................................................................................1699 Air Flow Control Actuator Removal and Installation.....................................................................................................................................................................................................1700 Air Flow Control Actuator Inspection...................................................................................................................................................................................................................1700 Air Intake Control Actuator Removal and Installation...................................................................................................................................................................................................1701 Air Intake Control Actuator Inspection.................................................................................................................................................................................................................1701 Actuator Linkage Inspection............................................................................................................................................................................................................................1701 Blower Motor Controller Removal and Installation.......................................................................................................................................................................................................1701 Blower Motor Controller Inspection.....................................................................................................................................................................................................................1701 HVAC Control Module Removal and Installation...........................................................................................................................................................................................................1702 Sunload Sensor Removal and Installation................................................................................................................................................................................................................1702 Sunload Sensor Inspection..............................................................................................................................................................................................................................1703 Outside Air Temperature Sensor Removal and Installation................................................................................................................................................................................................1703 Outside Air Temperature Sensor Inspection..............................................................................................................................................................................................................1703 Inside Air Temperature Sensor Removal and Installation.................................................................................................................................................................................................1703 Inside Air Temperature Sensor Inspection...............................................................................................................................................................................................................1703 Condenser Assembly On-Vehicle Inspection...............................................................................................................................................................................................................1703 Condenser Assembly Removal and Installation............................................................................................................................................................................................................1703 Receiver/Dryer Removal and Installation................................................................................................................................................................................................................1703 Evaporator Inspection..................................................................................................................................................................................................................................1703 Evaporator Temperature Sensor Removal and Installation.................................................................................................................................................................................................1704 Evaporator Temperature Sensor Inspection...............................................................................................................................................................................................................1704 Expansion Valve Removal and Installation...............................................................................................................................................................................................................1704 Expansion Valve Inspection.............................................................................................................................................................................................................................1704 A/C Refrigerant Pressure Sensor and Its Circuit Inspection.............................................................................................................................................................................................1704 A/C Refrigerant Pressure Sensor Removal and Installation...............................................................................................................................................................................................1704 Compressor Relay Inspection............................................................................................................................................................................................................................1704 Compressor Drive Belt Inspection and Adjustment........................................................................................................................................................................................................1704 Compressor Drive Belt Removal and Installation.........................................................................................................................................................................................................1704 Compressor Assembly Removal and Installation...........................................................................................................................................................................................................1704 Compressor Assembly Components.........................................................................................................................................................................................................................1704 Magnet Clutch Removal and Installation.................................................................................................................................................................................................................1704 Magnet Clutch Inspection...............................................................................................................................................................................................................................1704 Thermal Switch Inspection..............................................................................................................................................................................................................................1704 Thermal Switch Removal and Installation................................................................................................................................................................................................................1704 Relief Valve Inspection................................................................................................................................................................................................................................1704 Special Tools and Equipment................................................................................................................................................................................................................................1705 Special Tool...........................................................................................................................................................................................................................................1705 Restraint..............................................................................................................................................................................................................................................................1707 Precautions........................................................................................................................................................................................................................................................1709 Precautions....................................................................................................................................................................................................................................................1709 Precautions on Restraint...................................................................................................................................................................................................................................1709 Seat Belts.........................................................................................................................................................................................................................................................1710 Precautions....................................................................................................................................................................................................................................................1710 Precautions on Service and Diagnosis of Seat Belt..........................................................................................................................................................................................................1710 General Description............................................................................................................................................................................................................................................1710 Seat Belt Construction.....................................................................................................................................................................................................................................1710 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1711 Repair and Inspection Required after Accident..............................................................................................................................................................................................................1711 Repair Instructions............................................................................................................................................................................................................................................1711 Front Seat Belt Components.................................................................................................................................................................................................................................1711 Front Seat Belt Removal and Installation...................................................................................................................................................................................................................1712 Front Seat Belt Inspection.................................................................................................................................................................................................................................1713 Rear Seat Belt Components..................................................................................................................................................................................................................................1714 Rear Seat Belt Removal and Installation....................................................................................................................................................................................................................1715 Rear Seat Belt Inspection..................................................................................................................................................................................................................................1715 Specifications.................................................................................................................................................................................................................................................1715 Tightening Torque Specifications...........................................................................................................................................................................................................................1715 Air Bag System.....................................................................................................................................................................................................................................................1716 Precautions....................................................................................................................................................................................................................................................1716 Precautions on Service and Diagnosis of Air Bag System.....................................................................................................................................................................................................1716 Precautions on Handling and Storage of Air Bag System Components...........................................................................................................................................................................................1716 Precautions on Disposal of Air Bag and Seat Belt Pretensioner..............................................................................................................................................................................................1720 General Description............................................................................................................................................................................................................................................1720 Air Bag System Construction................................................................................................................................................................................................................................1720 Air Bag System Input / Output Table........................................................................................................................................................................................................................1721 Schematic and Routing Diagram..................................................................................................................................................................................................................................1722 Air Bag System Wiring Circuit Diagram......................................................................................................................................................................................................................1722 Component Location.............................................................................................................................................................................................................................................1724 Air Bag System Components, Wiring and Connectors Location..................................................................................................................................................................................................1724 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1725 Air Bag Diagnostic System Check............................................................................................................................................................................................................................1725 Air Bag Diagnostic System Check Flow.......................................................................................................................................................................................................................1725 DTC Table..................................................................................................................................................................................................................................................1726 DTC Check..................................................................................................................................................................................................................................................1727 DTC Clearance..............................................................................................................................................................................................................................................1727 Scan Tool Data.............................................................................................................................................................................................................................................1728 “AIR BAG” Warning Lamp Comes ON Steady.....................................................................................................................................................................................................................1728 “AIR BAG” Warning Lamp Does Not Come ON....................................................................................................................................................................................................................1730 “AIR BAG” Warning Lamp Flashes.............................................................................................................................................................................................................................1731 DTC B1013: SDM fault.......................................................................................................................................................................................................................................1732 DTC B1014: “AIR BAG” Warning Lamp Circuit Failure..........................................................................................................................................................................................................1732 DTC B1016: Power Source Voltage High.......................................................................................................................................................................................................................1733 DTC B1017: Power Source Voltage Low........................................................................................................................................................................................................................1735 DTC B1021: Front Air Bag Module Deployed...................................................................................................................................................................................................................1737 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed..............................................................................................................................................................................................1737 DTC B1026: Pretensioner Activated..........................................................................................................................................................................................................................1738 DTC B1027: Reusable Number Exceeded........................................................................................................................................................................................................................1739 DTC B1031: Driver Air Bag Initiator Circuit Resistance High................................................................................................................................................................................................1739 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low.................................................................................................................................................................................................1744 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground................................................................................................................................................................................................1749 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit.........................................................................................................................................................................................1754 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High.............................................................................................................................................................................................1759 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low..............................................................................................................................................................................................1762 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground.............................................................................................................................................................................................1765 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit......................................................................................................................................................................................1768 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.......................................................................................................................................................................1771 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low........................................................................................................................................................................1773 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.......................................................................................................................................................................1775 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit................................................................................................................................................................1777 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.......................................................................................................................................................................1779 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low........................................................................................................................................................................1782 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.......................................................................................................................................................................1785 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit................................................................................................................................................................1788 DTC B1071: Forward-Sensor Performance Problem..............................................................................................................................................................................................................1791 DTC B1072: Forward-Sensor Communication Error..............................................................................................................................................................................................................1791 DTC B1073: Forward-Sensor Circuit Short to Ground..........................................................................................................................................................................................................1791 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open...........................................................................................................................................................................................1793 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem......................................................................................................................................................................................1795 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error......................................................................................................................................................................................1795 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground..................................................................................................................................................................................1795 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open...................................................................................................................................................................1797 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID..........................................................................................................................................................................................1799 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1799 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1801 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1803 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1805 Inspection of Intermittent and Poor Connections............................................................................................................................................................................................................1808 Repair and Inspection Required after Accident..............................................................................................................................................................................................................1809 Repair Instructions............................................................................................................................................................................................................................................1811 Disabling Air Bag System...................................................................................................................................................................................................................................1811 Enabling Air Bag System....................................................................................................................................................................................................................................1812 SDM Removal and Installation...............................................................................................................................................................................................................................1813 SDM Inspection.............................................................................................................................................................................................................................................1813 Driver Air Bag (Inflator) Module Removal and Installation..................................................................................................................................................................................................1814 Driver Air Bag (Inflator) Module Inspection................................................................................................................................................................................................................1815 Passenger Air Bag (Inflator) Module Removal and Installation...............................................................................................................................................................................................1815 Passenger Air Bag (Inflator) Module Inspection.............................................................................................................................................................................................................1817 Side-Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................................................1817 Side-Air Bag (Inflator) Inspection.........................................................................................................................................................................................................................1819 Side Curtain-Air Bag (Inflator) Module Removal and Installation............................................................................................................................................................................................1819 Side Curtain-Air Bag (Inflator) Module Inspection..........................................................................................................................................................................................................1820 Forward-Sensor Removal and Installation....................................................................................................................................................................................................................1821 Forward-Sensor Inspection..................................................................................................................................................................................................................................1822 Side-Sensor Removal and Installation.......................................................................................................................................................................................................................1822 Side-Sensor Inspection.....................................................................................................................................................................................................................................1823 Passenger Air Bag (Inflator) Module Repair Harness Installation............................................................................................................................................................................................1823 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal..............................................................................................................................................................................................1824 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal...........................................................................................................................................................................1834 Specifications.................................................................................................................................................................................................................................................1835 Tightening Torque Specifications...........................................................................................................................................................................................................................1835 Special Tools and Equipment....................................................................................................................................................................................................................................1835 Use of Special Tools.......................................................................................................................................................................................................................................1835 Recommended Service Material...............................................................................................................................................................................................................................1837 Special Tool...............................................................................................................................................................................................................................................1837 Body, Cab and Accessories..............................................................................................................................................................................................................................................1839 Precautions........................................................................................................................................................................................................................................................1844 Precautions....................................................................................................................................................................................................................................................1844 Precautions on Body, Cab and Accessories...................................................................................................................................................................................................................1844 Precautions for Body Service...............................................................................................................................................................................................................................1844 Fastener Caution for Body Service..........................................................................................................................................................................................................................1844 Wiring Systems.....................................................................................................................................................................................................................................................1845 Precautions....................................................................................................................................................................................................................................................1845 Cautions in Body Electrical System Servicing...............................................................................................................................................................................................................1845 Precautions for Wiring System..............................................................................................................................................................................................................................1845 General Description............................................................................................................................................................................................................................................1846 Abbreviations..............................................................................................................................................................................................................................................1846 Wire / Connector Color Symbols.............................................................................................................................................................................................................................1847 Symbols and Marks..........................................................................................................................................................................................................................................1847 How to Read Connector Layout Diagram.......................................................................................................................................................................................................................1849 How to Read Connector Codes and Terminal Nos...............................................................................................................................................................................................................1850 How to Read Ground Point...................................................................................................................................................................................................................................1852 How to Read Power Supply Diagram...........................................................................................................................................................................................................................1853 How to Read System Circuit Diagram.........................................................................................................................................................................................................................1853 Connector Layout Diagram.......................................................................................................................................................................................................................................1855 Connector Layout Diagram...................................................................................................................................................................................................................................1855 Engine Compartment.........................................................................................................................................................................................................................................1855 E: Main harness, ECM GND wire (RHD) (DSL)..................................................................................................................................................................................................................1862 B: WTP wire / E: Main harness, ECM GND wire (LHD) (DSL)....................................................................................................................................................................................................1863 Instrument Panel...........................................................................................................................................................................................................................................1865 Door, Roof.................................................................................................................................................................................................................................................1870 Floor......................................................................................................................................................................................................................................................1872 Rear.......................................................................................................................................................................................................................................................1884 Ground Point...................................................................................................................................................................................................................................................1885 Ground (earth) Point.......................................................................................................................................................................................................................................1885 Power Supply Diagram...........................................................................................................................................................................................................................................1886 Power Supply Diagram (Petrol)..............................................................................................................................................................................................................................1886 Power Supply Diagram (DSL).................................................................................................................................................................................................................................1887 Fuses and the Protected Parts..............................................................................................................................................................................................................................1888 Fuses in Main Fuse Box (Petrol)............................................................................................................................................................................................................................1888 Fuses in Main Fuse Box (DSL)...............................................................................................................................................................................................................................1888 Individual Circuit Fuse Box No. 1 (Petrol).................................................................................................................................................................................................................1889 Individual Circuit Fuse Box No. 1 (DSL)....................................................................................................................................................................................................................1889 Individual Circuit Fuse Box No. 3 (DSL)....................................................................................................................................................................................................................1890 Individual Circuit Fuse Box No. 2 (In J/B).................................................................................................................................................................................................................1891 Junction Block (J/B) Connector / Fuse Layout...............................................................................................................................................................................................................1893 Junction Block Inner Circuit (Overview)....................................................................................................................................................................................................................1895 Junction Block Inner Circuit (Detail)......................................................................................................................................................................................................................1896 System Circuit Diagram.........................................................................................................................................................................................................................................1901 System Circuit Diagram.....................................................................................................................................................................................................................................1901 A-1 Cranking System Circuit Diagram (Petrol)...............................................................................................................................................................................................................1902 A-1 Cranking System Circuit Diagram (DSL)..................................................................................................................................................................................................................1903 A-2 Charging System Circuit Diagram (Petrol)...............................................................................................................................................................................................................1904 A-2 Charging System Circuit Diagram (DSL)..................................................................................................................................................................................................................1905 A-3 Ignition System Circuit Diagram (Petrol)...............................................................................................................................................................................................................1906 A-4 Cooling System Circuit Diagram (Petrol)................................................................................................................................................................................................................1907 A-4 Cooling System Circuit Diagram (DSL)...................................................................................................................................................................................................................1908 A-5 Engine and A/C Control System Circuit Diagram (Petrol).................................................................................................................................................................................................1909 A-5 Engine and A/C Control System (DSL)....................................................................................................................................................................................................................1914 A-6 A/T Control System Circuit Diagram.....................................................................................................................................................................................................................1919 A-7 Immobilizer System Circuit Diagram (Petrol)............................................................................................................................................................................................................1921 A-7 Immobilizer System Circuit Diagram (DSL)...............................................................................................................................................................................................................1922 A-8 Body Control System Circuit Diagram....................................................................................................................................................................................................................1923 A-9 Automated Manual Transaxle Control System Circuit Diagram (Petrol).....................................................................................................................................................................................1927 B-1 Windshield Wiper and Washer Circuit Diagram............................................................................................................................................................................................................1930 B-2 Rear Wiper and Washer Circuit Diagram..................................................................................................................................................................................................................1931 B-3 Rear Defogger Circuit Diagram..........................................................................................................................................................................................................................1932 B-4 Power Window Circuit Diagram...........................................................................................................................................................................................................................1933 B-5 Power Door Lock Circuit Diagram........................................................................................................................................................................................................................1934 B-6 Power Mirror Circuit Diagram...........................................................................................................................................................................................................................1936 B-7 Horn Circuit Diagram...................................................................................................................................................................................................................................1937 B-8 Seat Heater Circuit Diagram............................................................................................................................................................................................................................1938 B-9 Keyless Start System Circuit Diagram...................................................................................................................................................................................................................1939 C-1 Combination Meter Circuit Diagram (Meter)..............................................................................................................................................................................................................1940 C-2 Combination Meter Circuit Diagram (Indicator)..........................................................................................................................................................................................................1941 C-3 Combination Meter Circuit Diagram (Warning Light)......................................................................................................................................................................................................1942 D-1 Headlight System Circuit Diagram.......................................................................................................................................................................................................................1944 D-2 Position, Tail and Licence Plate Light System Circuit Diagram..........................................................................................................................................................................................1946 D-3 Front Fog Light System Circuit Diagram.................................................................................................................................................................................................................1947 D-4 Illumination Light System Circuit Diagram..............................................................................................................................................................................................................1948 D-5 Interior Light System Circuit Diagram..................................................................................................................................................................................................................1949 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram............................................................................................................................................................................................1950 D-7 Brake Light System Circuit Diagram.....................................................................................................................................................................................................................1952 D-8 Back-Up Light System Circuit Diagram...................................................................................................................................................................................................................1953 D-9 Headlight Beam Leveling System Circuit Diagram.........................................................................................................................................................................................................1954 D-10 Rear Fog Light Circuit Diagram........................................................................................................................................................................................................................1955 E-1 Heater System Circuit Diagram..........................................................................................................................................................................................................................1956 E-2 Auto A/C System Circuit Diagram........................................................................................................................................................................................................................1958 E-3 WTP Heater Circuit Diagram (DSL).......................................................................................................................................................................................................................1960 F-1 Air-Bag System Circuit Diagram.........................................................................................................................................................................................................................1962 F-2 Anti-Lock Brake System Circuit Diagram.................................................................................................................................................................................................................1964 F-3 Electronic Stability Program System Circuit Diagram....................................................................................................................................................................................................1966 F-4 Power Steering System Circuit Diagram..................................................................................................................................................................................................................1968 G-1 Audio System Circuit Diagram...........................................................................................................................................................................................................................1970 G-2 Multi Information Display / Accessory Socket System Circuit Diagram....................................................................................................................................................................................1971 G-4 Navigation System Circuit Diagram......................................................................................................................................................................................................................1972 List of Connector..............................................................................................................................................................................................................................................1973 List of Connectors.........................................................................................................................................................................................................................................1973 B Connector................................................................................................................................................................................................................................................1973 C Connector................................................................................................................................................................................................................................................1973 D Connector (DSL)..........................................................................................................................................................................................................................................1975 E Connector................................................................................................................................................................................................................................................1975 G Connector................................................................................................................................................................................................................................................1978 J Connector................................................................................................................................................................................................................................................1979 K Connector................................................................................................................................................................................................................................................1980 L Connector................................................................................................................................................................................................................................................1980 M Connector (SPORT)........................................................................................................................................................................................................................................1982 O Connector................................................................................................................................................................................................................................................1983 R Connector................................................................................................................................................................................................................................................1983 Lighting Systems...................................................................................................................................................................................................................................................1984 Component Location.............................................................................................................................................................................................................................................1984 Lighting System Components Location........................................................................................................................................................................................................................1984 Interior Light System Location.............................................................................................................................................................................................................................1985 Diagnostic Information and Procedures..........................................................................................................................................................................................................................1985 Headlight Symptom Diagnosis................................................................................................................................................................................................................................1985 DRL System Symptom Diagnosis (If Equipped).................................................................................................................................................................................................................1986 Headlight Leveling Symptom Diagnosis (If Equipped).........................................................................................................................................................................................................1986 Turn Signal and Hazard Warning Light Symptom Diagnosis.....................................................................................................................................................................................................1986 Clearance, Tail and License Plate Light Symptom Diagnosis..................................................................................................................................................................................................1987 Back-Up Light Symptom Diagnosis............................................................................................................................................................................................................................1987 Stop (Brake) Lamp Symptom Diagnosis........................................................................................................................................................................................................................1988 Front Fog Light (If Equipped) Symptom Diagnosis............................................................................................................................................................................................................1988 Rear Fog Light (If Equipped) Symptom Diagnosis.............................................................................................................................................................................................................1988 Illumination Cancel System (If Equipped) Symptom Diagnosis.................................................................................................................................................................................................1988 Interior Light Symptom Diagnosis...........................................................................................................................................................................................................................1989 DRL Operation Inspection (If Equipped).....................................................................................................................................................................................................................1989 Inspection of DRL Controller and Its Circuits (If Equipped)................................................................................................................................................................................................1989 Repair Instructions............................................................................................................................................................................................................................................1991 Headlight Housing Removal and Installation.................................................................................................................................................................................................................1991 Headlight Bulb Replacement.................................................................................................................................................................................................................................1991 Headlight Aiming Adjustment with Screen....................................................................................................................................................................................................................1991 Headlight Switch (in Lighting Switch) Removal and Installation.............................................................................................................................................................................................1993 Headlight Switch (in Lighting Switch) Inspection...........................................................................................................................................................................................................1993 Hazard Warning Switch Removal and Installation.............................................................................................................................................................................................................1993 Hazard Warning Switch Inspection...........................................................................................................................................................................................................................1994 Stop (Brake) Lamp Switch Inspection........................................................................................................................................................................................................................1994 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.....................................................................................................................................................................................1994 Turn Signal Light Switch (in Lighting Switch) Inspection...................................................................................................................................................................................................1994 Turn Signal and Hazard Warning Relay Removal and Installation..............................................................................................................................................................................................1994 Turn Signal and Hazard Warning Relay Inspection............................................................................................................................................................................................................1995 License Lamp Assembly Removal and Installation.............................................................................................................................................................................................................1995 Front Fog Light Assembly Removal and Installation (If Equipped)............................................................................................................................................................................................1996 Front Fog Light Bulb Replacement (If Equipped).............................................................................................................................................................................................................1996 Front Fog Light Switch Inspection (If Equipped)............................................................................................................................................................................................................1997 Front Fog Light Relay Inspection (If Equipped).............................................................................................................................................................................................................1997 Front Fog Light Aiming Adjustment with Screen (If Equipped)................................................................................................................................................................................................1997 Headlight Levering Switch (If Equipped) Inspection.........................................................................................................................................................................................................1998 Headlight Leveling Actuator Inspection (If Equipped).......................................................................................................................................................................................................1998 Rear Fog Light Switch Inspection...........................................................................................................................................................................................................................1999 Illumination Cancel Switch (If Equipped) Inspection........................................................................................................................................................................................................1999 Instrumentation / Driver Info. / Horn..............................................................................................................................................................................................................................2000 General Description............................................................................................................................................................................................................................................2000 CAN Communication Data of Combination Meter................................................................................................................................................................................................................2000 Auto Volume Control System Description (If Equipped).......................................................................................................................................................................................................2001 Schematic and Routing Diagram..................................................................................................................................................................................................................................2002 Combination Meter Circuit Diagram..........................................................................................................................................................................................................................2002 Component Location.............................................................................................................................................................................................................................................2004 Audio System Component Location............................................................................................................................................................................................................................2004 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2005 Speedometer and VSS Symptom Diagnosis......................................................................................................................................................................................................................2005 Tachometer Symptom Diagnosis...............................................................................................................................................................................................................................2005 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis...................................................................................................................................................................................................2005 Fuel Meter Symptom Diagnosis...............................................................................................................................................................................................................................2005 Low Fuel Warning Light Symptom Diagnosis...................................................................................................................................................................................................................2006 Oil Pressure Warning Light Symptom Diagnosis...............................................................................................................................................................................................................2006 Brake and Parking Brake Warning Light Symptom Diagnosis....................................................................................................................................................................................................2007 Seat Belt Reminder Light Symptom Diagnosis (If Equipped)...................................................................................................................................................................................................2007 A/T Shift Position Indicator (A/T Model Only) Symptom Diagnosis............................................................................................................................................................................................2008 Automated Manual Transaxle Shift Position Indicator (Automated Manual Transaxle Model Only) Symptom Diagnosis..............................................................................................................................................2008 Charge Warning Light Symptom Diagnosis.....................................................................................................................................................................................................................2008 Main Beam (High Beam) Indicator Symptom Diagnosis..........................................................................................................................................................................................................2008 Warning Buzzer Circuit Symptom Diagnosis...................................................................................................................................................................................................................2009 Cigarette Lighter Symptom Diagnosis (If Equipped)..........................................................................................................................................................................................................2009 Horn Symptom Diagnosis.....................................................................................................................................................................................................................................2009 Information Display Symptom Diagnosis (If Equipped)........................................................................................................................................................................................................2009 Clock Symptom Diagnosis (If Equipped)......................................................................................................................................................................................................................2010 Audio System Symptom Diagnosis (If Equipped)...............................................................................................................................................................................................................2011 Remote Audio Control Switch Symptom Diagnosis (If Equipped)................................................................................................................................................................................................2012 Navigation Symptom Diagnosis (If Equipped).................................................................................................................................................................................................................2013 Repair Instructions............................................................................................................................................................................................................................................2013 Ignition Switch Removal and Installation...................................................................................................................................................................................................................2013 Ignition Switch Inspection.................................................................................................................................................................................................................................2013 Combination Meter Removal and Installation.................................................................................................................................................................................................................2014 Fuel Level Sensor Removal and Installation.................................................................................................................................................................................................................2014 Fuel Level Sensor Inspection...............................................................................................................................................................................................................................2014 Oil Pressure Switch Removal and Installation...............................................................................................................................................................................................................2014 Oil Pressure Switch Inspection.............................................................................................................................................................................................................................2015 VSS Removal and Installation...............................................................................................................................................................................................................................2015 VSS Inspection.............................................................................................................................................................................................................................................2015 Engine Coolant Temperature (ECT) Sensor Inspection.........................................................................................................................................................................................................2015 Brake Fluid Level Switch Inspection........................................................................................................................................................................................................................2015 Parking Brake Switch Inspection............................................................................................................................................................................................................................2015 Door Switch (Front / Rear Door) Inspection.................................................................................................................................................................................................................2016 Rear End Door Switch Inspection............................................................................................................................................................................................................................2016 Outside Air Temperature Sensor Removal and Installation (If Equipped)......................................................................................................................................................................................2016 Outside Air Temperature Sensor Inspection (If Equipped)....................................................................................................................................................................................................2016 Instrument Panel Removal and Installation..................................................................................................................................................................................................................2017 Information Display (Clock) Removal and Installation.......................................................................................................................................................................................................2018 Audio Unit Removal and Installation........................................................................................................................................................................................................................2018 Front Speaker Removal and Installation.....................................................................................................................................................................................................................2018 Rear Speaker Removal and Installation (5 Door Model).......................................................................................................................................................................................................2019 Rear Speaker Removal and Installation (3 Door Model).......................................................................................................................................................................................................2019 GPS Antenna Removal and Installation (If Equipped).........................................................................................................................................................................................................2019 Horn Removal and Installation..............................................................................................................................................................................................................................2019 Horn Inspection............................................................................................................................................................................................................................................2020 Horn Relay Inspection......................................................................................................................................................................................................................................2020 Antenna Base Removal and Installation......................................................................................................................................................................................................................2020 Remote Audio Control Switch Inspection.....................................................................................................................................................................................................................2021 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped).............................................................................................................................................................................................2021 Specifications.................................................................................................................................................................................................................................................2021 Tightening Torque Specifications...........................................................................................................................................................................................................................2021 Wipers / Washers...................................................................................................................................................................................................................................................2022 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2022 Front Wiper and Washer Symptom Diagnosis...................................................................................................................................................................................................................2022 Rear Wiper and Washer Symptom Diagnosis (If Equipped)......................................................................................................................................................................................................2022 Repair Instructions............................................................................................................................................................................................................................................2023 Wipers and Washers Components..............................................................................................................................................................................................................................2023 Washer Tank and Washer Pump Removal and Installation.......................................................................................................................................................................................................2024 Washer Pump Inspection.....................................................................................................................................................................................................................................2024 Windshield Wiper Removal and Installation..................................................................................................................................................................................................................2025 Windshield Wiper Motor Inspection..........................................................................................................................................................................................................................2026 Rear Wiper Removal and Installation (If Equipped)..........................................................................................................................................................................................................2027 Rear Wiper Motor Inspection (If Equipped)..................................................................................................................................................................................................................2027 Windshield Wiper and Washer Switch Removal and Installation................................................................................................................................................................................................2028 Windshield Wiper and Washer Switch Inspection..............................................................................................................................................................................................................2029 Rear Wiper and Washer Switch Removal and Installation......................................................................................................................................................................................................2030 Rear Wiper and Washer Switch Inspection....................................................................................................................................................................................................................2030 Rear Wiper Relay Removal and Installation..................................................................................................................................................................................................................2030 Rear Wiper Relay Inspection................................................................................................................................................................................................................................2031 Specifications.................................................................................................................................................................................................................................................2031 Tightening Torque Specifications...........................................................................................................................................................................................................................2031 Glass / Windows / Mirrors..........................................................................................................................................................................................................................................2032 General Description............................................................................................................................................................................................................................................2032 Rear End Door Window Defogger System Description...........................................................................................................................................................................................................2032 Windshield Construction....................................................................................................................................................................................................................................2032 Rear Quarter Window Construction...........................................................................................................................................................................................................................2033 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2034 Rear End door Window Defogger Symptom Diagnosis............................................................................................................................................................................................................2034 Power Window Control System Symptom Diagnosis..............................................................................................................................................................................................................2034 Power Door Mirror Control System Symptom Diagnosis (If Equipped)...........................................................................................................................................................................................2035 Door Mirror Heater Symptom Diagnosis (If Equipped).........................................................................................................................................................................................................2035 Repair Instructions............................................................................................................................................................................................................................................2035 Windshield Removal and Installation........................................................................................................................................................................................................................2035 Rear Quarter Window Removal and Installation...............................................................................................................................................................................................................2039 Front Door Window Components...............................................................................................................................................................................................................................2042 Front Door Glass Removal and Installation..................................................................................................................................................................................................................2043 Front Door Window Regulator Removal and Installation.......................................................................................................................................................................................................2044 Front Door Window Regulator Inspection.....................................................................................................................................................................................................................2044 Rear Door Window Components................................................................................................................................................................................................................................2045 Rear Door Glass Removal and Installation...................................................................................................................................................................................................................2045 Rear Door Window Regulator Removal and Installation........................................................................................................................................................................................................2047 Rear Door Window Regulator Inspection......................................................................................................................................................................................................................2047 Rear End Door Window Components............................................................................................................................................................................................................................2047 Rear End Door Glass Removal and Installation...............................................................................................................................................................................................................2048 Rear End Door Window Defogger Switch Inspection............................................................................................................................................................................................................2048 Rear End Door Window Defogger Relay Inspection.............................................................................................................................................................................................................2049 Rear End Door Window Defogger Wire Inspection..............................................................................................................................................................................................................2049 Rear End Door Window Defogger Wire Repair..................................................................................................................................................................................................................2050 Power Window Main Switch Inspection........................................................................................................................................................................................................................2050 Power Window Sub Switch Inspection.........................................................................................................................................................................................................................2051 Door Mirror Components.....................................................................................................................................................................................................................................2052 Door Mirror Removal and Installation.......................................................................................................................................................................................................................2052 Power Door Mirror Switch Inspection (If Equipped)..........................................................................................................................................................................................................2052 Power Door Mirror Actuator Inspection (If Equipped)........................................................................................................................................................................................................2053 Door Mirror Heater Inspection (If Equipped)................................................................................................................................................................................................................2053 Special Tools and Equipment....................................................................................................................................................................................................................................2053 Recommended Service Material...............................................................................................................................................................................................................................2053 Security and Locks.................................................................................................................................................................................................................................................2054 General Description............................................................................................................................................................................................................................................2054 Key Coding Construction....................................................................................................................................................................................................................................2054 Rear End Door Opener System Description....................................................................................................................................................................................................................2054 Component Location.............................................................................................................................................................................................................................................2055 Power Door Lock and Keyless Entry System Component Location................................................................................................................................................................................................2055 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2056 Power Door Lock System Symptom Diagnosis...................................................................................................................................................................................................................2056 Power Door Lock System Operation Inspection................................................................................................................................................................................................................2056 Keyless Entry System Symptom Diagnosis (If Equipped).......................................................................................................................................................................................................2057 Keyless Entry System Operation Inspection..................................................................................................................................................................................................................2058 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped).................................................................................................................................................................................2058 Rear End Door Opener System Symptom Diagnosis..............................................................................................................................................................................................................2058 Rear End Door Opener System Operation Inspection...........................................................................................................................................................................................................2058 Repair Instructions............................................................................................................................................................................................................................................2059 Front Door Lock Assembly Components........................................................................................................................................................................................................................2059 Front Door Lock Assembly Removal and Installation..........................................................................................................................................................................................................2059 Front Door Lock Assembly Inspection........................................................................................................................................................................................................................2061 Power Door Lock Switch Inspection..........................................................................................................................................................................................................................2061 Door Key Cylinder Switch Inspection........................................................................................................................................................................................................................2061 Power Door Lock Actuator Inspection (If Equipped)..........................................................................................................................................................................................................2062 Rear Door Lock Assembly Components.........................................................................................................................................................................................................................2063 Rear Door Lock Assembly Removal and Installation...........................................................................................................................................................................................................2063 Rear Door Lock Assembly Inspection.........................................................................................................................................................................................................................2063 Rear End Door Lock Assembly Components.....................................................................................................................................................................................................................2064 Rear End Door Lock Assembly Removal and Installation.......................................................................................................................................................................................................2064 Rear End Door Lock Assembly Inspection.....................................................................................................................................................................................................................2065 Rear End Door Opener Switch Inspection.....................................................................................................................................................................................................................2065 Replacement of Transmitter Battery.........................................................................................................................................................................................................................2065 Programming Transmitter Code...............................................................................................................................................................................................................................2066 Keyless Entry Receiver Removal and Installation............................................................................................................................................................................................................2066 Keyless Entry Receiver and Its Circuit Inspection..........................................................................................................................................................................................................2067 Specifications.................................................................................................................................................................................................................................................2068 Tightening Torque Specifications...........................................................................................................................................................................................................................2068 Special Tools and Equipment....................................................................................................................................................................................................................................2068 Recommended Service Material...............................................................................................................................................................................................................................2068 Seats..............................................................................................................................................................................................................................................................2069 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2069 Front Seat Heater Symptom Diagnosis (If Equipped)..........................................................................................................................................................................................................2069 Repair Instructions............................................................................................................................................................................................................................................2070 Front Seat Components......................................................................................................................................................................................................................................2070 Front Seat Removal and Installation........................................................................................................................................................................................................................2071 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)..............................................................................................................................................................................2071 Front Seat Heater Wire Inspection (If Equipped)............................................................................................................................................................................................................2071 Rear Seat Components.......................................................................................................................................................................................................................................2072 Rear Seat Removal and Installation.........................................................................................................................................................................................................................2074 Specifications.................................................................................................................................................................................................................................................2074 Tightening Torque Specifications...........................................................................................................................................................................................................................2074 Special Tools and Equipment....................................................................................................................................................................................................................................2074 Recommended Service Material...............................................................................................................................................................................................................................2074 Interior Trim......................................................................................................................................................................................................................................................2075 Repair Instructions............................................................................................................................................................................................................................................2075 Floor Carpet Removal and Installation......................................................................................................................................................................................................................2075 Head Lining Removal and Installation.......................................................................................................................................................................................................................2075 Console Box Components.....................................................................................................................................................................................................................................2077 Specifications.................................................................................................................................................................................................................................................2077 Tightening Torque Specifications...........................................................................................................................................................................................................................2077 Hood / Fenders / Doors.............................................................................................................................................................................................................................................2078 Repair Instructions............................................................................................................................................................................................................................................2078 Hood Removal and Installation..............................................................................................................................................................................................................................2078 Hood Inspection and Adjustment.............................................................................................................................................................................................................................2078 Front Fender Components....................................................................................................................................................................................................................................2079 Front Fender Removal and Installation......................................................................................................................................................................................................................2079 Front Door Assembly Components.............................................................................................................................................................................................................................2080 Front Door Assembly Removal and Installation...............................................................................................................................................................................................................2080 Rear Door Assembly Components..............................................................................................................................................................................................................................2081 Rear Door Assembly Removal and Installation................................................................................................................................................................................................................2082 Rear End Door Assembly Components..........................................................................................................................................................................................................................2082 Rear End Door Assembly Removal and Installation............................................................................................................................................................................................................2083 Specifications.................................................................................................................................................................................................................................................2084 Tightening Torque Specifications...........................................................................................................................................................................................................................2084 Special Tools and Equipment....................................................................................................................................................................................................................................2084 Recommended Service Material...............................................................................................................................................................................................................................2084 Body Structure.....................................................................................................................................................................................................................................................2085 Repair Instructions............................................................................................................................................................................................................................................2085 Front Bumper and Rear Bumper Components....................................................................................................................................................................................................................2085 Cowl Top Components........................................................................................................................................................................................................................................2087 Specifications.................................................................................................................................................................................................................................................2088 Body Dimensions............................................................................................................................................................................................................................................2088 Panel Clearance............................................................................................................................................................................................................................................2097 Paint / Coatings...................................................................................................................................................................................................................................................2098 General Description............................................................................................................................................................................................................................................2098 Anti-Corrosion Treatment Construction......................................................................................................................................................................................................................2098 Plastic Parts Finishing....................................................................................................................................................................................................................................2098 Component Location.............................................................................................................................................................................................................................................2099 Sealant Application Areas..................................................................................................................................................................................................................................2099 Under Coating Application Areas............................................................................................................................................................................................................................2104 Anti-Corrosion Compound Application Area...................................................................................................................................................................................................................2106 Exterior Trim......................................................................................................................................................................................................................................................2108 Repair Instructions............................................................................................................................................................................................................................................2108 Roof Molding Components....................................................................................................................................................................................................................................2108 Splash Guard (If Equipped) Components......................................................................................................................................................................................................................2109 Control Systems........................................................................................................................................................................................................................................................2111 Precautions........................................................................................................................................................................................................................................................2114 Precautions....................................................................................................................................................................................................................................................2114 Precautions for Control Systems............................................................................................................................................................................................................................2114 Body Electrical Control System.....................................................................................................................................................................................................................................2115 Precautions....................................................................................................................................................................................................................................................2115 Precautions in Diagnosing Trouble..........................................................................................................................................................................................................................2115 General Description............................................................................................................................................................................................................................................2115 BCM General Description....................................................................................................................................................................................................................................2115 CAN Communication System Description.......................................................................................................................................................................................................................2115 Alarm Indicator Lamp Description...........................................................................................................................................................................................................................2116 Schematic and Routing Diagram..................................................................................................................................................................................................................................2116 Body Electrical Control System Wiring Circuit Diagram......................................................................................................................................................................................................2116 Connector Layout Diagram of BCM and Junction Block Assembly................................................................................................................................................................................................2119 Component Location.............................................................................................................................................................................................................................................2120 BCM and Related System Component Location..................................................................................................................................................................................................................2120 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2121 BCM Self-Diagnosis Function................................................................................................................................................................................................................................2121 Body Electrical Control System Check.......................................................................................................................................................................................................................2122 Scan Tool Data.............................................................................................................................................................................................................................................2124 DTC Table..................................................................................................................................................................................................................................................2126 DTC Check..................................................................................................................................................................................................................................................2126 DTC Clearance..............................................................................................................................................................................................................................................2128 BCM Power Circuit and Ground Circuit Check.................................................................................................................................................................................................................2128 DTC B1133 (No. 1133): Battery Voltage Too High.............................................................................................................................................................................................................2129 DTC B1141 / B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction................................................................................................................................................2130 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction............................................................................................................................................................................................2131 DTC B1157 (No. 1157): Air Bag Deployment Signal Input......................................................................................................................................................................................................2133 DTC B1170 (No. 1170): EEPROM Access Error..................................................................................................................................................................................................................2133 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module................................................................................................................................................................2134 DTC U1073 (No. 1073): Control Module Communication Bus Off.................................................................................................................................................................................................2136 DTC U1100 (No. 1100): Lost Communication with ECM..........................................................................................................................................................................................................2137 DTC U1101 (No. 1101): Lost Communication with TCM..........................................................................................................................................................................................................2139 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module.................................................................................................................................................................................2141 Inspection of BCM and its Circuits.........................................................................................................................................................................................................................2143 Repair Instructions............................................................................................................................................................................................................................................2152 BCM (Included in Junction Block Assembly) Removal and Installation.........................................................................................................................................................................................2152 Outside Air Temperature Sensor Removal and Installation....................................................................................................................................................................................................2152 Outside Air Temperature Sensor Inspection..................................................................................................................................................................................................................2152 Special Tools and Equipment....................................................................................................................................................................................................................................2152 Special Tool...............................................................................................................................................................................................................................................2152 Immobilizer Control System.........................................................................................................................................................................................................................................2153 Petrol Model...................................................................................................................................................................................................................................................2153 Precautions................................................................................................................................................................................................................................................2153 Precautions in Diagnosing Troubles.....................................................................................................................................................................................................................2153 Precaution in Replacing ECM............................................................................................................................................................................................................................2153 Precautions in Handling Immobilizer Control System.....................................................................................................................................................................................................2153 General Description........................................................................................................................................................................................................................................2154 Immobilizer Control System Introduction................................................................................................................................................................................................................2154 On-Board Diagnostic System Description (Self- diagnosis Function)......................................................................................................................................................................................2154 Schematic and Routing Diagram..............................................................................................................................................................................................................................2155 Immobilizer Control System Wiring Circuit Diagram......................................................................................................................................................................................................2155 Component Location.........................................................................................................................................................................................................................................2156 Immobilizer Control System Components Location.........................................................................................................................................................................................................2156 Diagnostic Information and Procedures......................................................................................................................................................................................................................2156 Immobilizer Control System Check.......................................................................................................................................................................................................................2156 Diagnostic Trouble Code (DTC) Check....................................................................................................................................................................................................................2157 Diagnostic Trouble Code (DTC) Clearance................................................................................................................................................................................................................2157 Diagnostic Trouble Code (DTC) Table....................................................................................................................................................................................................................2158 Scan Tool Data.........................................................................................................................................................................................................................................2158 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop....................................................................................................................................................................2159 Immobilizer Indicator Lamp Remains ON after Engine Starts..............................................................................................................................................................................................2160 DTC P1614: Transponder Response Error..................................................................................................................................................................................................................2160 DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only)...............................................................................................................................................................2161 DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only)...........................................................................................................................................................2162 DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)................................................................................................................2163 DTC P1621: Immobilizer Communication Line Error........................................................................................................................................................................................................2164 DTC P1622: EEPROM Error................................................................................................................................................................................................................................2165 DTC P1623: Unregistered Transponder....................................................................................................................................................................................................................2165 DTC P1625: Immobilizer Antenna Error...................................................................................................................................................................................................................2166 DTC P1636: Immobilizer Information Registration Failure................................................................................................................................................................................................2166 DTC P1638: Immobilizer Information Mismatched..........................................................................................................................................................................................................2167 Inspection of Immobilizer Control Module (ICM) and Its Circuit.........................................................................................................................................................................................2169 Repair Instructions........................................................................................................................................................................................................................................2171 Immobilizer Control Module (ICM) Removal and Installation..............................................................................................................................................................................................2171 Registration of the Ignition Key.......................................................................................................................................................................................................................2171 Procedure after ECM Replacement........................................................................................................................................................................................................................2171 Special Tools and Equipment................................................................................................................................................................................................................................2172 Special Tool...........................................................................................................................................................................................................................................2172 Diesel Model...................................................................................................................................................................................................................................................2173 Precautions................................................................................................................................................................................................................................................2173 Precautions in Diagnosing Troubles.....................................................................................................................................................................................................................2173 Precautions in Handling Immobilizer Control System.....................................................................................................................................................................................................2173 Precautions after Replacing ECM or Immobilizer Control Module..........................................................................................................................................................................................2174 General Description........................................................................................................................................................................................................................................2174 Immobilizer Control System Operation Description.......................................................................................................................................................................................................2174 Immobilizer Control System Components Description......................................................................................................................................................................................................2175 On-Board Diagnostic System Description.................................................................................................................................................................................................................2176 Schematic and Routing Diagram..............................................................................................................................................................................................................................2177 Immobilizer Control System Wiring Circuit Diagram......................................................................................................................................................................................................2177 Diagnostic Information and Procedures......................................................................................................................................................................................................................2178 Immobilizer Control System Check.......................................................................................................................................................................................................................2178 DTC Check..............................................................................................................................................................................................................................................2179 DTC Clearance..........................................................................................................................................................................................................................................2179 DTC Table..............................................................................................................................................................................................................................................2179 Scan Tool Data.........................................................................................................................................................................................................................................2180 SVS Lamp Does Not Come ON with Ignition Switch ON and Engine Stop......................................................................................................................................................................................2181 SVS Lamp Remains On after Ignition Switch ON...........................................................................................................................................................................................................2182 DTC B1000: Immobilizer Control Module Internal Failure.................................................................................................................................................................................................2182 DTC B3040: W-Line Communication Failure................................................................................................................................................................................................................2183 DTC B3042: W-Line Circuit Malfunction Shorted to Ground................................................................................................................................................................................................2183 DTC B3043: W-Line Circuit Malfunction Shorted to Battery...............................................................................................................................................................................................2184 DTC B3055: No Transponder..............................................................................................................................................................................................................................2185 DTC B3056: No Fix Code Registered......................................................................................................................................................................................................................2186 DTC B3057: No Password Registered......................................................................................................................................................................................................................2186 DTC B3059: No Request from ECM.........................................................................................................................................................................................................................2186 DTC B3060: Incorrect Transponder Detected..............................................................................................................................................................................................................2187 DTC B3061: Transponder Communication Failure...........................................................................................................................................................................................................2188 DTC B3077: Read-Only Transponder Detected..............................................................................................................................................................................................................2189 DTC P1610: Secret Key / Password Not Programed.........................................................................................................................................................................................................2190 DTC P1611: Password Is Not Matched.....................................................................................................................................................................................................................2190 DTC P1612 / P1613: No Signal from Immobilizer Control Module / Immobilizer System Malfunction..........................................................................................................................................................2190 DTC P1614: Incorrect Signal from Immobilizer Control Module............................................................................................................................................................................................2191 DTC P1615: Steering Lock Unit Communication Error (for Vehicle with Keyless Start System)..............................................................................................................................................................2191 DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System)...........................................................................................................................................................2192 DTC P1618: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System)................................................................................................................................................2193 Registration Procedure of Immobilizer Control System Components........................................................................................................................................................................................2194 Inspection of Immobilizer Control Module and Its Circuit...............................................................................................................................................................................................2194 Repair Instructions........................................................................................................................................................................................................................................2195 Immobilizer Control Module Removal and Installation....................................................................................................................................................................................................2195 How to Register Ignition Key...........................................................................................................................................................................................................................2196 Procedure after Immobilizer Control Module Replacement.................................................................................................................................................................................................2196 Procedure after ECM Replacement........................................................................................................................................................................................................................2196 Special Tools and Equipment................................................................................................................................................................................................................................2196 Special Tool...........................................................................................................................................................................................................................................2196 Keyless Start System...............................................................................................................................................................................................................................................2197 Precautions....................................................................................................................................................................................................................................................2197 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................2197 General Description............................................................................................................................................................................................................................................2197 Keyless Start System Description...........................................................................................................................................................................................................................2197 Parts and Functions........................................................................................................................................................................................................................................2199 Keyless Engine Start Function..............................................................................................................................................................................................................................2200 Door Lock Function of Keyless Start System.................................................................................................................................................................................................................2201 Operation Area of Remote Controller........................................................................................................................................................................................................................2202 Alarm Function.............................................................................................................................................................................................................................................2203 CAN Communication of Keyless Start System..................................................................................................................................................................................................................2203 Schematic and Routing Diagram..................................................................................................................................................................................................................................2204 Keyless Start System Electric Wiring Circuit Diagram.......................................................................................................................................................................................................2204 Diagnostic Information and Procedures..........................................................................................................................................................................................................................2205 Self-Diagnosis Function....................................................................................................................................................................................................................................2205 Keyless Start System Diagnosis Introduction................................................................................................................................................................................................................2205 Keyless Start System Check.................................................................................................................................................................................................................................2205 Customer questionnaire (example)...........................................................................................................................................................................................................................2206 Key Indicator Lamp Check...................................................................................................................................................................................................................................2206 DTC Check..................................................................................................................................................................................................................................................2207 DTC Table..................................................................................................................................................................................................................................................2208 DTC Clearance..............................................................................................................................................................................................................................................2208 Keyless Start System Symptom Diagnosis.....................................................................................................................................................................................................................2209 Keyless Start System Operation Inspection..................................................................................................................................................................................................................2210 Door Lock Operation Check (Keyless Start System)...........................................................................................................................................................................................................2210 Inspection of Keyless Start Control Module and Its Circuits................................................................................................................................................................................................2211 No DTC Detection After Performing DTC Check................................................................................................................................................................................................................2215 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.)...................................................................................................................................................2216 Keyless Start Control Module Power and Ground Circuit Check................................................................................................................................................................................................2218 DTC No. 11: Communication Error with Steering Lock Unit....................................................................................................................................................................................................2219 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction.........................................................................................................................................................2220 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)........................................................................................................................................2220 DTC No. 31: Lost Communication with BCM....................................................................................................................................................................................................................2221 DTC No. 33: Control Module Communication Bus Off...........................................................................................................................................................................................................2223 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure..........................................................................................................................................................2225 Repair Instructions............................................................................................................................................................................................................................................2227 Antennas and Request Switches Removal and Installation.....................................................................................................................................................................................................2227 Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection.............................................................................................................................................................................2228 Steering Lock Unit Removal and Installation................................................................................................................................................................................................................2228 Steering Lock Unit Inspection..............................................................................................................................................................................................................................2228 Front Door Lock Switch Inspection..........................................................................................................................................................................................................................2228 Keyless start control module Removal and Installation......................................................................................................................................................................................................2229 Remote Controller Inspection...............................................................................................................................................................................................................................2229 Replacement of Remote Controller Battery...................................................................................................................................................................................................................2230 Registration Procedure for Remote Controller ID Code.......................................................................................................................................................................................................2230 COPYRIGHT..............................................................................................................................................................................................................................................................2232 BOOKCOVER_VOL1.........................................................................................................................................................................................................................................................2233 BOOKCOVER_VOL2.........................................................................................................................................................................................................................................................2234
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