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Suzuki Swift RS413 RS415 RS416 RS413D Supplementary Service Manual – PDF DOWNLOAD
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Description
Suzuki Swift RS413 RS415 RS416 RS413D Supplementary Service Manual – PDF DOWNLOAD
FILE DETAILS:
Suzuki Swift RS413 RS415 RS416 RS413D Supplementary Service Manual – PDF DOWNLOAD
Language : English
Pages : 658
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Suzuki Swift RS413 RS415 RS416 RS413D Supplementary Service Manual – PDF DOWNLOAD
START.................................................................................................................................................................................................................................................................. 1 IMPORTANT.............................................................................................................................................................................................................................................................. 1 FOREWORD............................................................................................................................................................................................................................................................... 3 TABLE OF CONTENTS...................................................................................................................................................................................................................................................... 5 Precautions............................................................................................................................................................................................................................................................ 7 Precautions........................................................................................................................................................................................................................................................ 8 Precautions.................................................................................................................................................................................................................................................... 8 Precaution for Vehicle Equipped with ESP‚ System........................................................................................................................................................................................................... 8 Brake Caution.............................................................................................................................................................................................................................................. 8 General Information.................................................................................................................................................................................................................................................... 9 General Information................................................................................................................................................................................................................................................ 11 General Description............................................................................................................................................................................................................................................ 11 Abbreviations.............................................................................................................................................................................................................................................. 11 Maintenance and Lubrication........................................................................................................................................................................................................................................ 13 Scheduled Maintenance.......................................................................................................................................................................................................................................... 13 Maintenance Schedule under Normal Driving Conditions (Petrol Engine Model)................................................................................................................................................................................. 13 Repair Instructions............................................................................................................................................................................................................................................ 14 Brake Discs and Pads Inspection............................................................................................................................................................................................................................ 14 Special Tools and Equipment.................................................................................................................................................................................................................................... 14 Recommended Fluids and Lubricants (Petrol Engine Model).................................................................................................................................................................................................... 14 Engine................................................................................................................................................................................................................................................................. 15 Precautions........................................................................................................................................................................................................................................................ 24 For M13, M15 and M16 Engines................................................................................................................................................................................................................................... 24 Precautions................................................................................................................................................................................................................................................ 24 Precautions for Engine................................................................................................................................................................................................................................. 24 For Z13DT Engine............................................................................................................................................................................................................................................... 25 Precautions................................................................................................................................................................................................................................................ 25 Precautions for Engine................................................................................................................................................................................................................................. 25 Engine General Information and Diagnosis........................................................................................................................................................................................................................... 26 For M13, M15 and M16 Engines................................................................................................................................................................................................................................... 26 Precautions................................................................................................................................................................................................................................................ 26 Precautions of Electric Throttle Body System Calibration (Electric Throttle Body Model)................................................................................................................................................................ 26 General Description........................................................................................................................................................................................................................................ 27 CAN Communication System Description................................................................................................................................................................................................................... 27 Description of Electric Throttle Body System (Electric Throttle Body Model)............................................................................................................................................................................ 30 Fuel Cut Control Description (M16A Engine)............................................................................................................................................................................................................. 31 Generator Control System Description (M16A Engine)..................................................................................................................................................................................................... 31 Electronic Control System Description.................................................................................................................................................................................................................. 32 Engine and Emission Control Input / Output Table....................................................................................................................................................................................................... 40 Schematic and Routing Diagram.............................................................................................................................................................................................................................. 41 Engine and Emission Control System Diagram............................................................................................................................................................................................................. 41 Component Location......................................................................................................................................................................................................................................... 43 Electronic Control System Components Location.......................................................................................................................................................................................................... 43 Diagnostic Information and Procedures...................................................................................................................................................................................................................... 44 DTC Table.............................................................................................................................................................................................................................................. 44 Fail-Safe Table........................................................................................................................................................................................................................................ 49 Scan Tool Data......................................................................................................................................................................................................................................... 51 Engine Symptom Diagnosis............................................................................................................................................................................................................................... 56 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)........................................................................................................................................ 68 Malfunction Indicator Lamp Remains ON after Engine Starts.............................................................................................................................................................................................. 70 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction...................................................................................................................................................................................................... 72 DTC P0620: Generator Control Circuit................................................................................................................................................................................................................... 76 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High......................................................................................................................................................................................... 78 DTC P1674: CAN Communication (Bus Off Error)........................................................................................................................................................................................................... 80 DTC P1675: CAN Communication (Transmission Error)...................................................................................................................................................................................................... 90 DTC P1676: CAN Communication (Reception Error for TCM (A/T or Automated Manual Transaxle model))....................................................................................................................................................... 99 DTC P1678: CAN Communication (Reception Error for BCM).................................................................................................................................................................................................102 DTC P1685: CAN Communication (Reception Error ESP‚ Control Module (ESP‚ model))........................................................................................................................................................................109 DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed (Electric Throttle Body Model)...............................................................................................................................................112 Inspection of ECM and Its Circuits.....................................................................................................................................................................................................................113 Repair Instructions........................................................................................................................................................................................................................................139 Idle Speed / Idle Air Control (IAC) Duty Inspection (Non-electric Throttle Body Model).................................................................................................................................................................139 Idle Speed and IAC Throttle Valve Opening Inspection (Electric Throttle Body Model)....................................................................................................................................................................140 Special Tools and Equipment................................................................................................................................................................................................................................141 Special Tool...........................................................................................................................................................................................................................................141 Engine Electrical Devices..........................................................................................................................................................................................................................................142 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................142 Repair Instructions........................................................................................................................................................................................................................................142 Electric Throttle Body Assembly On-Vehicle Inspection (Electric Throttle Body Model)...................................................................................................................................................................142 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation......................................................................................................................................................................................145 Vehicle Speed Sensor (VSS) Inspection (If Equipped)....................................................................................................................................................................................................146 Specifications.............................................................................................................................................................................................................................................146 Tightening Torque Specifications.......................................................................................................................................................................................................................146 Engine Mechanical..................................................................................................................................................................................................................................................147 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................147 Repair Instructions........................................................................................................................................................................................................................................147 Air Cleaner Components.................................................................................................................................................................................................................................147 Cylinder Head Cover Removal and Installation...........................................................................................................................................................................................................148 Throttle Body and Intake Manifold Components...........................................................................................................................................................................................................150 Throttle Body On-Vehicle Inspection (For M16A Engine Model)............................................................................................................................................................................................151 Electric Throttle Body Assembly Removal and Installation...............................................................................................................................................................................................151 Throttle Body Cleaning (For M16A Engine Model).........................................................................................................................................................................................................152 Intake Manifold Removal and Installation (For M16A Engine Model).......................................................................................................................................................................................152 Engine Mountings Components (For M16A Engine Model)....................................................................................................................................................................................................154 Engine Assembly Removal and Installation (For M16A Engine Model).......................................................................................................................................................................................155 Camshaft, Tappet and Shim Inspection...................................................................................................................................................................................................................158 Valve Spring Inspection................................................................................................................................................................................................................................161 Pistons, Piston Rings, Connecting Rods and Cylinders Components........................................................................................................................................................................................162 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation..........................................................................................................................................................................163 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly..........................................................................................................................................................................164 Cylinders, Pistons and Piston Rings Inspection.........................................................................................................................................................................................................166 Piston Pins and Connecting Rods Inspection.............................................................................................................................................................................................................168 Crank Pin and Connecting Rod Bearings Inspection.......................................................................................................................................................................................................170 Main Bearings, Crankshaft and Cylinder Block Components................................................................................................................................................................................................173 Main Bearings, Crankshaft and Cylinder Block Removal and Installation..................................................................................................................................................................................174 Crankshaft Inspection..................................................................................................................................................................................................................................177 Main Bearings Inspection...............................................................................................................................................................................................................................179 Cylinder Block Inspection..............................................................................................................................................................................................................................185 Specifications.............................................................................................................................................................................................................................................185 Tightening Torque Specifications.......................................................................................................................................................................................................................185 Special Tools and Equipment................................................................................................................................................................................................................................186 Recommended Service Material...........................................................................................................................................................................................................................186 Special Tool...........................................................................................................................................................................................................................................186 Engine Lubrication System..........................................................................................................................................................................................................................................187 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................187 General Description........................................................................................................................................................................................................................................187 Engine Lubrication Description.........................................................................................................................................................................................................................187 Repair Instructions........................................................................................................................................................................................................................................189 Heat Exchanger Components (For M16A Engine Model)......................................................................................................................................................................................................189 Heat Exchanger On-Vehicle Inspection (For M16A Engine Model)...........................................................................................................................................................................................189 Heat Exchanger Removal and Installation (For M16A Engine Model)........................................................................................................................................................................................189 Specifications.............................................................................................................................................................................................................................................190 Tightening Torque Specifications.......................................................................................................................................................................................................................190 Special Tools and Equipment................................................................................................................................................................................................................................190 Recommended Service Material...........................................................................................................................................................................................................................190 Engine Cooling System..............................................................................................................................................................................................................................................191 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................191 Schematic and Routing Diagram..............................................................................................................................................................................................................................191 Coolant Circulation....................................................................................................................................................................................................................................191 Repair Instructions........................................................................................................................................................................................................................................193 Cooling System Components..............................................................................................................................................................................................................................193 Thermostat Removal and Installation....................................................................................................................................................................................................................195 Water Pump / Generator Drive Belt Tension Inspection and Adjustment....................................................................................................................................................................................195 Water Pump / Generator Drive Belt Removal and Installation.............................................................................................................................................................................................195 Specifications.............................................................................................................................................................................................................................................195 Tightening Torque Specifications.......................................................................................................................................................................................................................195 Ignition System....................................................................................................................................................................................................................................................196 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................196 Schematic and Routing Diagram..............................................................................................................................................................................................................................196 Ignition System Wiring Circuit Diagram.................................................................................................................................................................................................................196 Component Location.........................................................................................................................................................................................................................................197 Ignition System Components Location....................................................................................................................................................................................................................197 Repair Instructions........................................................................................................................................................................................................................................198 Spark Plug Inspection..................................................................................................................................................................................................................................198 Ignition Timing Inspection.............................................................................................................................................................................................................................198 Special Tools and Equipment................................................................................................................................................................................................................................199 Special Tool...........................................................................................................................................................................................................................................199 Charging System....................................................................................................................................................................................................................................................200 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................200 General Description........................................................................................................................................................................................................................................200 Generator Description (For 80A Type)...................................................................................................................................................................................................................200 Diagnostic Information and Procedures......................................................................................................................................................................................................................201 Battery Inspection.....................................................................................................................................................................................................................................201 Generator Symptom Diagnosis............................................................................................................................................................................................................................202 Generator Test (Undercharged Battery Check) (For 80A Type).............................................................................................................................................................................................202 Generator Test (Overcharged Battery Check).............................................................................................................................................................................................................203 Repair Instructions........................................................................................................................................................................................................................................204 Jump Starting in Case of Emergency.....................................................................................................................................................................................................................204 Battery Dismounting and Remounting.....................................................................................................................................................................................................................204 Water Pump / Generator Drive Belt Tension Inspection and Adjustment....................................................................................................................................................................................205 Water Pump / Generator Drive Belt Removal and Installation.............................................................................................................................................................................................206 Generator Unit Components..............................................................................................................................................................................................................................207 Generator Dismounting and Remounting...................................................................................................................................................................................................................208 Generator Components...................................................................................................................................................................................................................................208 Generator Inspection...................................................................................................................................................................................................................................209 Specifications.............................................................................................................................................................................................................................................210 Charging System Specifications.........................................................................................................................................................................................................................210 Tightening Torque Specifications.......................................................................................................................................................................................................................211 Exhaust System.....................................................................................................................................................................................................................................................212 For M13, M15 and M16 Engines...................................................................................................................................................................................................................................212 Repair Instructions........................................................................................................................................................................................................................................212 Exhaust System Components..............................................................................................................................................................................................................................212 Exhaust Manifold Removal and Installation..............................................................................................................................................................................................................214 Specifications.............................................................................................................................................................................................................................................217 Tightening Torque Specifications.......................................................................................................................................................................................................................217 Suspension.............................................................................................................................................................................................................................................................219 Precautions........................................................................................................................................................................................................................................................221 Precautions....................................................................................................................................................................................................................................................221 Precautions on Suspension..................................................................................................................................................................................................................................221 Suspension General Diagnosis.......................................................................................................................................................................................................................................222 Specifications.................................................................................................................................................................................................................................................222 Wheel Alignment Specifications.............................................................................................................................................................................................................................222 Front Suspension...................................................................................................................................................................................................................................................223 General Description............................................................................................................................................................................................................................................223 Front Suspension Construction (Other Than M16A Engine Model)...............................................................................................................................................................................................223 Front Suspension Construction (For M16A Engine Model)......................................................................................................................................................................................................224 Repair Instructions............................................................................................................................................................................................................................................225 Front Wheel Alignment Inspection and Adjustment............................................................................................................................................................................................................225 Front Strut Assembly Components............................................................................................................................................................................................................................227 Front Strut Assembly Removal and Installation..............................................................................................................................................................................................................228 Front Wheel Hub and Steering Knuckle Components............................................................................................................................................................................................................230 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation...............................................................................................................................................................................230 Suspension Control Arm / Bushing Removal and Installation..................................................................................................................................................................................................234 Front Suspension Frame, Stabilizer Bar and/or Bushings Components (Other Than M16A Engine Model)...........................................................................................................................................................235 Front Suspension Frame, Stabilizer Bar and/or Bushings Components (For M16A Engine Model)..................................................................................................................................................................236 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation............................................................................................................................................................................236 Specifications.................................................................................................................................................................................................................................................241 Tightening Torque Specifications...........................................................................................................................................................................................................................241 Special Tools and Equipment....................................................................................................................................................................................................................................242 Special Tool...............................................................................................................................................................................................................................................242 Rear Suspension....................................................................................................................................................................................................................................................243 General Description............................................................................................................................................................................................................................................243 Rear Suspension Construction (For Drum Brake Type).........................................................................................................................................................................................................243 Rear Suspension Construction (For Disc Brake Type).........................................................................................................................................................................................................244 Repair Instructions............................................................................................................................................................................................................................................245 Rear Shock Absorber Removal and Installation...............................................................................................................................................................................................................245 Rear Axle Removal and Installation (For Disc Brake Type)...................................................................................................................................................................................................246 Rear Wheel Hub Components (For Disc Brake Type)............................................................................................................................................................................................................249 Rear Wheel Hub Removal and Installation (For Disc Brake Type)..............................................................................................................................................................................................249 Rear Wheel Disc, bolt and Bearing Inspection...............................................................................................................................................................................................................250 Spindle Removal and Installation (For Disc Brake Type).....................................................................................................................................................................................................251 Spindle Inspection (For Disc Brake Type)...................................................................................................................................................................................................................251 Rear Suspension Fasteners Inspection.......................................................................................................................................................................................................................251 Specifications.................................................................................................................................................................................................................................................252 Tightening Torque Specifications...........................................................................................................................................................................................................................252 Special Tools and Equipment....................................................................................................................................................................................................................................252 Special Tool...............................................................................................................................................................................................................................................252 Wheels and Tires...................................................................................................................................................................................................................................................253 Repair Instructions............................................................................................................................................................................................................................................253 General Balance Procedures.................................................................................................................................................................................................................................253 Tire Rotation..............................................................................................................................................................................................................................................253 Wheel Removal and Installation.............................................................................................................................................................................................................................254 Sealant Extraction of Sealed Tire..........................................................................................................................................................................................................................255 Specifications.................................................................................................................................................................................................................................................256 Wheels and Tires Specifications............................................................................................................................................................................................................................256 Tightening Torque Specifications...........................................................................................................................................................................................................................256 Driveline / Axle.......................................................................................................................................................................................................................................................257 Precautions........................................................................................................................................................................................................................................................258 Precautions....................................................................................................................................................................................................................................................258 Precautions for Driveline / Axle...........................................................................................................................................................................................................................258 Drive Shaft / Axle.................................................................................................................................................................................................................................................259 Component Location.............................................................................................................................................................................................................................................259 Front Drive Shaft Assembly Components Location.............................................................................................................................................................................................................259 Repair Instructions............................................................................................................................................................................................................................................260 Front Drive Shaft Components (M16A Engine and Z13DT Engine Models).........................................................................................................................................................................................260 Front Drive Shaft Disassembly and Assembly.................................................................................................................................................................................................................261 Center Shaft and Center Bearing Support Disassembly and Assembly...........................................................................................................................................................................................268 Front Drive Shaft Inspection...............................................................................................................................................................................................................................271 Specifications.................................................................................................................................................................................................................................................271 Tightening Torque Specifications...........................................................................................................................................................................................................................271 Special Tools and Equipment....................................................................................................................................................................................................................................271 Recommended Service Material...............................................................................................................................................................................................................................271 Special Tool...............................................................................................................................................................................................................................................271 Brakes.................................................................................................................................................................................................................................................................273 Precautions........................................................................................................................................................................................................................................................277 Precautions....................................................................................................................................................................................................................................................277 Precautions for Brakes.....................................................................................................................................................................................................................................277 Brake Control System and Diagnosis.................................................................................................................................................................................................................................278 Precautions....................................................................................................................................................................................................................................................278 Precautions on Brake.......................................................................................................................................................................................................................................278 General Description............................................................................................................................................................................................................................................278 Brakes Construction........................................................................................................................................................................................................................................278 Front Brake Hose / Pipe Construction (For M16A Engine Model)...............................................................................................................................................................................................280 Rear Brake Hose / Pipe Construction........................................................................................................................................................................................................................281 Diagnostic Information and Procedures..........................................................................................................................................................................................................................282 Brakes Symptom Diagnosis...................................................................................................................................................................................................................................282 Repair Instructions............................................................................................................................................................................................................................................284 Air Bleeding of Brake System...............................................................................................................................................................................................................................284 Brake Booster Components...................................................................................................................................................................................................................................285 Specifications.................................................................................................................................................................................................................................................286 Tightening Torque Specifications...........................................................................................................................................................................................................................286 Special Tools and Equipment....................................................................................................................................................................................................................................286 Recommended Service Material...............................................................................................................................................................................................................................286 Front Brakes.......................................................................................................................................................................................................................................................287 Repair Instructions............................................................................................................................................................................................................................................287 Front Disc Brake Components................................................................................................................................................................................................................................287 Specifications.................................................................................................................................................................................................................................................288 Tightening Torque Specifications...........................................................................................................................................................................................................................288 Special Tools and Equipment....................................................................................................................................................................................................................................288 Recommended Service Material...............................................................................................................................................................................................................................288 Rear Brakes........................................................................................................................................................................................................................................................289 Disc Brake Type................................................................................................................................................................................................................................................289 Repair Instructions........................................................................................................................................................................................................................................289 Rear Disc Brake Components.............................................................................................................................................................................................................................289 Rear Disc Brake Pad Removal and Installation...........................................................................................................................................................................................................290 Rear Disc Brake Caliper Removal and Installation.......................................................................................................................................................................................................291 Rear Disc Brake Pad Inspection.........................................................................................................................................................................................................................293 Rear Disc Brake Caliper Disassembly and Assembly.......................................................................................................................................................................................................293 Rear Disc Brake Caliper Inspection.....................................................................................................................................................................................................................295 Rear Brake Disc Removal and Installation...............................................................................................................................................................................................................295 Rear Brake Disc Inspection.............................................................................................................................................................................................................................296 Specifications.............................................................................................................................................................................................................................................297 Tightening Torque Specifications.......................................................................................................................................................................................................................297 Special Tools and Equipment................................................................................................................................................................................................................................297 Recommended Service Material...........................................................................................................................................................................................................................297 Special Tool...........................................................................................................................................................................................................................................297 Parking Brake......................................................................................................................................................................................................................................................298 General Description............................................................................................................................................................................................................................................298 Parking Brake Cable Construction (For M16A Engine Model)...................................................................................................................................................................................................298 Repair Instructions............................................................................................................................................................................................................................................299 Parking Brake Inspection and Adjustment....................................................................................................................................................................................................................299 Parking Brake Cable Removal and Installation...............................................................................................................................................................................................................300 Specifications.................................................................................................................................................................................................................................................300 Tightening Torque Specifications...........................................................................................................................................................................................................................300 ABS................................................................................................................................................................................................................................................................301 General Description............................................................................................................................................................................................................................................301 ABS Hydraulic Unit / Control Module Assembly Description...................................................................................................................................................................................................301 Schematic and Routing Diagram..................................................................................................................................................................................................................................302 ABS Schematic..............................................................................................................................................................................................................................................302 ABS Wiring Circuit Diagram.................................................................................................................................................................................................................................303 Repair Instructions............................................................................................................................................................................................................................................304 Rear Wheel Speed Sensor Ring Removal and Installation......................................................................................................................................................................................................304 Electronic Stability Program.......................................................................................................................................................................................................................................305 Precautions....................................................................................................................................................................................................................................................305 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................305 Precautions in On-Vehicle Service..........................................................................................................................................................................................................................305 Precautions in Hydraulic Unit Operation Check..............................................................................................................................................................................................................305 Precautions in Sensor Calibration..........................................................................................................................................................................................................................305 Precautions in Speedometer Test or Other Tests.............................................................................................................................................................................................................306 General Description............................................................................................................................................................................................................................................306 Electronic Stability Program Description...................................................................................................................................................................................................................306 ESP‚ Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................................................306 Warning Lamp, Indicator Lamp Description...................................................................................................................................................................................................................307 CAN Communication System Description.......................................................................................................................................................................................................................307 CAN Communication System For Electronic Stability Program Description......................................................................................................................................................................................308 Schematic and Routing Diagram..................................................................................................................................................................................................................................309 Electronic Stability Program Schematic.....................................................................................................................................................................................................................309 Electronic Stability Program Wiring Circuit Diagram........................................................................................................................................................................................................310 Component Location.............................................................................................................................................................................................................................................312 Electronic Stability Program Component Location............................................................................................................................................................................................................312 Diagnostic Information and Procedures..........................................................................................................................................................................................................................313 Electronic Stability Program Check.........................................................................................................................................................................................................................313 ESP‚ Warning lamp Check....................................................................................................................................................................................................................................315 ABS Warning Lamp Check (with ESP‚ Model)...................................................................................................................................................................................................................315 EBD Warning Lamp (Brake Warning Lamp) Check (with ESP‚ Model)..............................................................................................................................................................................................316 DTC Check..................................................................................................................................................................................................................................................316 DTC Table..................................................................................................................................................................................................................................................316 DTC Clearance..............................................................................................................................................................................................................................................319 Fail-Safe Table............................................................................................................................................................................................................................................320 Scan Tool Data.............................................................................................................................................................................................................................................322 ESP‚ Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................................................323 ESP‚ Warning Lamp Comes ON Steady..........................................................................................................................................................................................................................324 ABS Warning Lamp Does Not Come ON at Ignition Switch ON (with ESP‚ Model)..................................................................................................................................................................................325 ABS Warning Lamp Comes ON Steady (with ESP‚ Model).........................................................................................................................................................................................................326 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady (with ESP‚ Model)....................................................................................................................................................................................326 Serial Data Link Circuit Check.............................................................................................................................................................................................................................328 DTC C1016: Stop Lamp Switch Circuit Failure................................................................................................................................................................................................................330 DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor in Yaw Rate / G Sensor Assembly Failure..............................................................................................................................................................331 DTC C1018: Brake Fluid Level Switch Failure................................................................................................................................................................................................................332 DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure.............................................................................................................................................................................................333 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Encoder Failure............................................................................................334 DTC C1024: Steering Angle Sensor Circuit Failure...........................................................................................................................................................................................................336 DTC C1027: ESP‚ OFF Switch Circuit Failure.................................................................................................................................................................................................................336 DTC C1028: Master Cylinder Pressure Sensor Circuit Failure.................................................................................................................................................................................................337 DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure...............................................................................................................................................................................................338 DTC C1037: Steering Angle Sensor Power Supply Failure......................................................................................................................................................................................................339 DTC C1038: Steering Angle Sensor Detect Rolling Counter Failure from ESP‚ Control Module...................................................................................................................................................................340 DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure...................................................................................................................................................................................................341 DTC C1040: Stability Control System Function Failure.......................................................................................................................................................................................................341 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....342 DTC C1057: ESP‚ Control Module Power Supply Circuit Failure................................................................................................................................................................................................343 DTC C1061: Pump Motor and/or Motor Driver Circuit Failure..................................................................................................................................................................................................344 DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure..............................................................................................................................................................................................345 DTC 1071: ESP‚ Control Module Internal Defect..............................................................................................................................................................................................................346 DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly............................................................................................................................................................................................347 DTC C1075 / 1076 / 1078: Steering Angle Sensor / Master Cylinder Pressure Sensor / Lateral G Sensor in Yaw Rate / G Sensor Assembly Calibration Incomplete.................................................................................................348 DTC C1090: ECM Detect Rolling Counter Failure from ESP‚ Control Module.....................................................................................................................................................................................349 DTC C1091: ECM Data in CAN Line Failure....................................................................................................................................................................................................................349 DTC U1073: Control Module Communication Bus Off............................................................................................................................................................................................................350 DTC U1100: Lost Communication with ECM (Reception Error)...................................................................................................................................................................................................351 DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error).................................................................................................................................................................................352 DTC U1140: Lost Communication with BCM (Reception Error)...................................................................................................................................................................................................353 Repair Instructions............................................................................................................................................................................................................................................355 ESP‚ Hydraulic Unit Operation Check........................................................................................................................................................................................................................355 Sensor Calibration.........................................................................................................................................................................................................................................355 ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................................................356 ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation.....................................................................................................................................................................................357 Front / Rear Wheel Speed Sensor On-Vehicle Inspection......................................................................................................................................................................................................358 Front Wheel Speed Sensor Removal and Installation..........................................................................................................................................................................................................359 Front Wheel Speed Sensor Inspection........................................................................................................................................................................................................................360 Rear Wheel Speed Sensor Removal and Installation...........................................................................................................................................................................................................360 Rear Wheel Speed Sensor Inspection.........................................................................................................................................................................................................................361 Front Wheel Encoder On-Vehicle Inspection..................................................................................................................................................................................................................362 Front Wheel Encoder Removal and Installation...............................................................................................................................................................................................................362 Rear Wheel Encoder On-Vehicle Inspection...................................................................................................................................................................................................................362 Rear Wheel Encoder Removal and Installation................................................................................................................................................................................................................362 Master Cylinder Pressure Sensor On-Vehicle Inspection......................................................................................................................................................................................................362 Yaw Rate / G Sensor Assembly On-Vehicle Inspection.........................................................................................................................................................................................................363 Yaw Rate / G Sensor Assembly Removal and Installation......................................................................................................................................................................................................364 Yaw Rate / G Sensor Inspection.............................................................................................................................................................................................................................365 Steering Angle Sensor On-Vehicle Inspection................................................................................................................................................................................................................365 Steering Angle Sensor Removal and Installation.............................................................................................................................................................................................................366 Steering Angle Sensor Inspection...........................................................................................................................................................................................................................366 ESP‚ OFF Switch Removal and Installation...................................................................................................................................................................................................................366 ESP‚ OFF Switch Inspection.................................................................................................................................................................................................................................366 Specifications.................................................................................................................................................................................................................................................367 Tightening Torque Specifications...........................................................................................................................................................................................................................367 Special Tools and Equipment....................................................................................................................................................................................................................................367 Special Tool...............................................................................................................................................................................................................................................367 Transmission / Transaxle...............................................................................................................................................................................................................................................369 Precautions........................................................................................................................................................................................................................................................375 Precautions....................................................................................................................................................................................................................................................375 Precautions on Transmission / Transaxle....................................................................................................................................................................................................................375 Manual Transmission/Transaxle......................................................................................................................................................................................................................................376 For M15 and M16 Engines Model..................................................................................................................................................................................................................................376 General Description........................................................................................................................................................................................................................................376 Manual Transaxle Construction and Servicing............................................................................................................................................................................................................376 Repair Instructions........................................................................................................................................................................................................................................378 Manual Transaxle Assembly Components...................................................................................................................................................................................................................378 Differential Components................................................................................................................................................................................................................................379 Differential Disassembly and Assembly..................................................................................................................................................................................................................380 Specifications.............................................................................................................................................................................................................................................382 Tightening Torque Specifications.......................................................................................................................................................................................................................382 Special Tools and Equipment................................................................................................................................................................................................................................382 Recommended Service Material...........................................................................................................................................................................................................................382 Special Tool...........................................................................................................................................................................................................................................382 Clutch.............................................................................................................................................................................................................................................................383 Repair Instructions............................................................................................................................................................................................................................................383 Clutch Pedal and Clutch Pedal Bracket Components...........................................................................................................................................................................................................383 Steering...............................................................................................................................................................................................................................................................385 Steering Wheel and Column..........................................................................................................................................................................................................................................387 Repair Instructions............................................................................................................................................................................................................................................387 Steering Wheel and Column Construction.....................................................................................................................................................................................................................387 Contact Coil Cable Assembly Removal and Installation.......................................................................................................................................................................................................388 Steering Angle Sensor Removal and Installation.............................................................................................................................................................................................................389 Steering Angle Sensor Inspection...........................................................................................................................................................................................................................389 Specifications.................................................................................................................................................................................................................................................389 Tightening Torque Specifications...........................................................................................................................................................................................................................389 Power Assisted Steering System.....................................................................................................................................................................................................................................390 General Description............................................................................................................................................................................................................................................390 On-Board Diagnostic System Description.....................................................................................................................................................................................................................390 Schematic and Routing Diagram..................................................................................................................................................................................................................................391 EPS System Wiring Circuit Diagram..........................................................................................................................................................................................................................391 Diagnostic Information and Procedures..........................................................................................................................................................................................................................392 “EPS” Warning Lamp Check...................................................................................................................................................................................................................................392 DTC Table..................................................................................................................................................................................................................................................393 Serial Data Link Circuit Check.............................................................................................................................................................................................................................394 DTC C1114: Torque Sensor 5 V Power Supply Circuit Failure..................................................................................................................................................................................................396 DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure.................................................................................................................................................................................................398 DTC C1122: Engine Speed Signal Circuit Failure.............................................................................................................................................................................................................400 Inspection of P/S Control Module and Its Circuits..........................................................................................................................................................................................................401 Repair Instructions............................................................................................................................................................................................................................................406 Steering Gear Case Assembly Components.....................................................................................................................................................................................................................406 Torque Sensor Inspection...................................................................................................................................................................................................................................407 Motor Assembly Inspection..................................................................................................................................................................................................................................408 Specifications.................................................................................................................................................................................................................................................409 Tightening Torque Specifications...........................................................................................................................................................................................................................409 Special Tools and Equipment....................................................................................................................................................................................................................................409 Recommended Service Material...............................................................................................................................................................................................................................409 HVAC...................................................................................................................................................................................................................................................................411 Precautions........................................................................................................................................................................................................................................................414 Precautions....................................................................................................................................................................................................................................................414 Precautions on HVAC........................................................................................................................................................................................................................................414 Heater and Ventilation.............................................................................................................................................................................................................................................415 Repair Instructions............................................................................................................................................................................................................................................415 Air Intake Control Actuator Inspection.....................................................................................................................................................................................................................415 Air Conditioning System............................................................................................................................................................................................................................................416 Automatic Type.................................................................................................................................................................................................................................................416 Precautions................................................................................................................................................................................................................................................416 A/C System Caution.....................................................................................................................................................................................................................................416 Precautions in Diagnosing Trouble......................................................................................................................................................................................................................416 Precautions on Servicing A/C System....................................................................................................................................................................................................................416 General Description........................................................................................................................................................................................................................................416 Auto A/C System Description............................................................................................................................................................................................................................416 HVAC Control Module Operation Description..............................................................................................................................................................................................................418 Refrigerant Type Identification........................................................................................................................................................................................................................418 Sub-Cool A/C System Description........................................................................................................................................................................................................................418 A/C Operation Description..............................................................................................................................................................................................................................418 On-Board Diagnostic System Description.................................................................................................................................................................................................................419 Schematic and Routing Diagram..............................................................................................................................................................................................................................419 Major Components of A/C System.........................................................................................................................................................................................................................419 A/C System Wiring Diagram..............................................................................................................................................................................................................................420 Diagnostic Information and Procedures......................................................................................................................................................................................................................422 A/C System Symptom Diagnosis...........................................................................................................................................................................................................................422 Abnormal Noise Symptom Diagnosis of A/C System.........................................................................................................................................................................................................425 DTC Check..............................................................................................................................................................................................................................................425 DTC Clearance..........................................................................................................................................................................................................................................427 DTC Table..............................................................................................................................................................................................................................................427 Fail-Safe Table........................................................................................................................................................................................................................................428 Scan Tool Data.........................................................................................................................................................................................................................................429 Air Conditioning System Check..........................................................................................................................................................................................................................431 Visual Inspection......................................................................................................................................................................................................................................433 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction................................................................................................................................................................................433 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction........................................................................................................................................................................435 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction...............................................................................................................................................................................................436 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction...............................................................................................................................................................438 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction..................................................................................................................................................................440 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction.................................................................................................................................................................................442 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction....................................................................................................................................................................................444 DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction........................................................................................................................................................................................446 DTC B1546: A/C Refrigerant Pressure Malfunction........................................................................................................................................................................................................447 DTC B1551: Serial Communication Circuit Malfunction....................................................................................................................................................................................................448 DTC B1552: Serial Communication Signal Malfunction.....................................................................................................................................................................................................449 DTC B1553: CAN Communication Signal Malfunction........................................................................................................................................................................................................450 DTC B1557: Vehicle Speed Sensor Signal Malfunction.....................................................................................................................................................................................................450 DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction........................................................................................................................................................................................450 DTC B1562: Outside Air Temperature Sensor Signal Malfunction...........................................................................................................................................................................................451 DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction..........................................................................................................................................................................................451 Inspection of HVAC Control Module and Its Circuit......................................................................................................................................................................................................452 A/C System Performance Inspection......................................................................................................................................................................................................................454 A/C System Inspection at ECM...........................................................................................................................................................................................................................454 Repair Instructions........................................................................................................................................................................................................................................454 Operation Procedure for Refrigerant Charge.............................................................................................................................................................................................................454 HVAC Unit Components...................................................................................................................................................................................................................................455 HVAC Unit Removal and Installation.....................................................................................................................................................................................................................456 Temperature Control Actuator Removal and Installation..................................................................................................................................................................................................456 Temperature Control Actuator Inspection................................................................................................................................................................................................................456 Air Flow Control Actuator Removal and Installation.....................................................................................................................................................................................................457 Air Flow Control Actuator Inspection...................................................................................................................................................................................................................457 Air Intake Control Actuator Removal and Installation...................................................................................................................................................................................................458 Air Intake Control Actuator Inspection.................................................................................................................................................................................................................458 Actuator Linkage Inspection............................................................................................................................................................................................................................458 Blower Motor Controller Removal and Installation.......................................................................................................................................................................................................458 Blower Motor Controller Inspection.....................................................................................................................................................................................................................458 HVAC Control Module Removal and Installation...........................................................................................................................................................................................................459 Sunload Sensor Removal and Installation................................................................................................................................................................................................................459 Sunload Sensor Inspection..............................................................................................................................................................................................................................460 Outside Air Temperature Sensor Removal and Installation................................................................................................................................................................................................460 Outside Air Temperature Sensor Inspection..............................................................................................................................................................................................................460 Inside Air Temperature Sensor Removal and Installation.................................................................................................................................................................................................460 Inside Air Temperature Sensor Inspection...............................................................................................................................................................................................................460 Condenser Assembly On-Vehicle Inspection...............................................................................................................................................................................................................460 Condenser Assembly Removal and Installation............................................................................................................................................................................................................460 Desiccant Removal and Installation.....................................................................................................................................................................................................................460 Evaporator Inspection..................................................................................................................................................................................................................................460 Evaporator Temperature Sensor Removal and Installation.................................................................................................................................................................................................461 Evaporator Temperature Sensor Inspection...............................................................................................................................................................................................................461 Expansion Valve Removal and Installation...............................................................................................................................................................................................................461 Expansion Valve Inspection.............................................................................................................................................................................................................................461 A/C Refrigerant Pressure Sensor and Its Circuit Inspection.............................................................................................................................................................................................461 A/C Refrigerant Pressure Sensor Removal and Installation...............................................................................................................................................................................................461 Compressor Relay Inspection............................................................................................................................................................................................................................461 Compressor Drive Belt Inspection and Adjustment........................................................................................................................................................................................................461 Compressor Drive Belt Removal and Installation.........................................................................................................................................................................................................461 Compressor Assembly Removal and Installation...........................................................................................................................................................................................................461 Compressor Assembly Components.........................................................................................................................................................................................................................461 Magnet Clutch Removal and Installation.................................................................................................................................................................................................................461 Magnet Clutch Inspection...............................................................................................................................................................................................................................461 Thermal Switch Inspection..............................................................................................................................................................................................................................461 Thermal Switch Removal and Installation................................................................................................................................................................................................................461 Relief Valve Inspection................................................................................................................................................................................................................................461 Special Tools and Equipment................................................................................................................................................................................................................................462 Special Tool...........................................................................................................................................................................................................................................462 Body, Cab and Accessories..............................................................................................................................................................................................................................................463 Precautions........................................................................................................................................................................................................................................................468 Precautions....................................................................................................................................................................................................................................................468 Precautions on Body, Cab and Accessories...................................................................................................................................................................................................................468 Precautions for Body Service...............................................................................................................................................................................................................................468 Fastener Caution for Body Service..........................................................................................................................................................................................................................468 Wiring Systems.....................................................................................................................................................................................................................................................469 General Description............................................................................................................................................................................................................................................469 Abbreviations..............................................................................................................................................................................................................................................469 Harness Routing and Connector Layout Diagram...................................................................................................................................................................................................................470 Connector Layout Diagram...................................................................................................................................................................................................................................470 Engine Compartment.........................................................................................................................................................................................................................................470 E: Main harness (RHD) (DSL)................................................................................................................................................................................................................................477 E: Main harness (LHD) (DSL)................................................................................................................................................................................................................................478 Instrument Panel...........................................................................................................................................................................................................................................479 Door, Roof.................................................................................................................................................................................................................................................484 Floor......................................................................................................................................................................................................................................................486 Rear.......................................................................................................................................................................................................................................................498 Power Supply Diagram...........................................................................................................................................................................................................................................499 Individual Circuit Fuse Box No. 1 (Petrol).................................................................................................................................................................................................................499 Individual Circuit Fuse Box No. 1 (DSL)....................................................................................................................................................................................................................499 Individual Circuit Fuse Box No. 2 (In J/B).................................................................................................................................................................................................................500 Junction Block Inner Circuit (Detail)......................................................................................................................................................................................................................503 System Circuit Diagram.........................................................................................................................................................................................................................................508 System Circuit Diagram.....................................................................................................................................................................................................................................508 A-1 Cranking System Circuit Diagram (DSL)..................................................................................................................................................................................................................509 A-2 Charging System Circuit Diagram (Petrol)...............................................................................................................................................................................................................510 A-3 Ignition System Circuit Diagram (Petrol)...............................................................................................................................................................................................................511 A-4 Cooling System Circuit Diagram (Petrol)................................................................................................................................................................................................................512 A-4 Cooling System Circuit Diagram (DSL)...................................................................................................................................................................................................................513 A-5 Engine and A/C Control System Circuit Diagram (Petrol).................................................................................................................................................................................................514 A-5 Engine and A/C Control System (DSL)....................................................................................................................................................................................................................519 A-6 A/T Control System Circuit Diagram.....................................................................................................................................................................................................................524 A-7 Immobilizer System Circuit Diagram (Petrol)............................................................................................................................................................................................................526 A-7 Immobilizer System Circuit Diagram (DSL)...............................................................................................................................................................................................................527 A-8 Body Control System Circuit Diagram....................................................................................................................................................................................................................528 A-9 Automated Manual Transaxle Control System Circuit Diagram (Petrol).....................................................................................................................................................................................532 B-1 Windshield Wiper and Washer Circuit Diagram............................................................................................................................................................................................................535 B-5 Power Door Lock Circuit Diagram........................................................................................................................................................................................................................536 B-9 Keyless Start System Circuit Diagram...................................................................................................................................................................................................................538 C-1 Combination Meter Circuit Diagram (Meter)..............................................................................................................................................................................................................539 C-2 Combination Meter Circuit Diagram (Indicator)..........................................................................................................................................................................................................540 C-3 Combination Meter Circuit Diagram (Warning Light)......................................................................................................................................................................................................541 D-1 Headlight System Circuit Diagram.......................................................................................................................................................................................................................543 D-2 Position, Tail and Licence Plate Light System Circuit Diagram..........................................................................................................................................................................................545 D-4 Illumination Light System Circuit Diagram..............................................................................................................................................................................................................546 D-7 Brake Light System Circuit Diagram.....................................................................................................................................................................................................................547 D-8 Back-Up Light System Circuit Diagram...................................................................................................................................................................................................................548 D-9 Headlight Beam Leveling System Circuit Diagram.........................................................................................................................................................................................................549 D-10 Rear Fog Light Circuit Diagram........................................................................................................................................................................................................................550 E-1 Heater System Circuit Diagram..........................................................................................................................................................................................................................551 E-2 Auto A/C System Circuit Diagram........................................................................................................................................................................................................................553 E-3 PTC Heater Circuit Diagram (DSL).......................................................................................................................................................................................................................555 F-2 Anti-Lock Brake System Circuit Diagram.................................................................................................................................................................................................................557 F-3 Electronic Stability Program System Circuit Diagram....................................................................................................................................................................................................559 F-4 Power Steering System Circuit Diagram..................................................................................................................................................................................................................561 G-1 Audio System Circuit Diagram...........................................................................................................................................................................................................................563 G-2 Multi Information Display / Accessory Socket System Circuit Diagram....................................................................................................................................................................................564 List of Connectors.............................................................................................................................................................................................................................................565 List of Connectors.........................................................................................................................................................................................................................................565 C Connector................................................................................................................................................................................................................................................565 E Connector................................................................................................................................................................................................................................................566 G Connector................................................................................................................................................................................................................................................569 L Connector................................................................................................................................................................................................................................................570 M Connector (SPORT)........................................................................................................................................................................................................................................572 R Connector................................................................................................................................................................................................................................................572 Lighting Systems...................................................................................................................................................................................................................................................573 Component Location.............................................................................................................................................................................................................................................573 Lighting System Components Location........................................................................................................................................................................................................................573 Repair Instructions............................................................................................................................................................................................................................................574 Front Fog Light Assembly Removal and Installation (If Equipped)............................................................................................................................................................................................574 Illumination Cancel Switch (If Equipped) Inspection........................................................................................................................................................................................................574 Instrumentation / Driver Info. / Horn..............................................................................................................................................................................................................................575 General Description............................................................................................................................................................................................................................................575 CAN Communication Data of Combination Meter................................................................................................................................................................................................................575 Auto Volume Control System Description (If Equipped).......................................................................................................................................................................................................576 Schematic and Routing Diagram..................................................................................................................................................................................................................................577 Combination Meter Circuit Diagram..........................................................................................................................................................................................................................577 Diagnostic Information and Procedures..........................................................................................................................................................................................................................579 Speedometer and VSS Symptom Diagnosis......................................................................................................................................................................................................................579 Oil Pressure Warning Light Symptom Diagnosis...............................................................................................................................................................................................................579 Brake and Parking Brake Warning Light Symptom Diagnosis....................................................................................................................................................................................................580 Information Display Symptom Diagnosis (If Equipped)........................................................................................................................................................................................................580 Audio System Symptom Diagnosis (If Equipped)...............................................................................................................................................................................................................582 Repair Instructions............................................................................................................................................................................................................................................584 VSS Removal and Installation...............................................................................................................................................................................................................................584 VSS Inspection.............................................................................................................................................................................................................................................584 Remote Audio Control Switch Inspection.....................................................................................................................................................................................................................584 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped).............................................................................................................................................................................................584 Glass / Windows / Mirrors..........................................................................................................................................................................................................................................585 Repair Instructions............................................................................................................................................................................................................................................585 Rear End Door Window Defogger Switch Inspection............................................................................................................................................................................................................585 Security and Locks.................................................................................................................................................................................................................................................586 Diagnostic Information and Procedures..........................................................................................................................................................................................................................586 Power Door Lock System Operation Inspection................................................................................................................................................................................................................586 Repair Instructions............................................................................................................................................................................................................................................586 Power Door Lock Actuator Inspection (If Equipped)..........................................................................................................................................................................................................586 Seats..............................................................................................................................................................................................................................................................588 Repair Instructions............................................................................................................................................................................................................................................588 Front Seat Components......................................................................................................................................................................................................................................588 Front Seat Removal and Installation........................................................................................................................................................................................................................589 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)..............................................................................................................................................................................589 Front Seat Heater Wire Inspection (If Equipped)............................................................................................................................................................................................................589 Rear Seat Components.......................................................................................................................................................................................................................................590 Specifications.................................................................................................................................................................................................................................................592 Tightening Torque Specifications...........................................................................................................................................................................................................................592 Special Tools and Equipment....................................................................................................................................................................................................................................592 Recommended Service Material...............................................................................................................................................................................................................................592 Body Structure.....................................................................................................................................................................................................................................................593 Repair Instructions............................................................................................................................................................................................................................................593 Front Bumper and Rear Bumper Components....................................................................................................................................................................................................................593 Cowl Top Components........................................................................................................................................................................................................................................595 Paint / Coatings...................................................................................................................................................................................................................................................596 Component Location.............................................................................................................................................................................................................................................596 Sealant Application Areas..................................................................................................................................................................................................................................596 Under Coating Application Areas............................................................................................................................................................................................................................601 Control systems........................................................................................................................................................................................................................................................603 Precautions........................................................................................................................................................................................................................................................606 Precautions....................................................................................................................................................................................................................................................606 Precautions for Control Systems............................................................................................................................................................................................................................606 Body Electrical Control System.....................................................................................................................................................................................................................................607 Precautions....................................................................................................................................................................................................................................................607 Precautions in Diagnosing Trouble..........................................................................................................................................................................................................................607 General Description............................................................................................................................................................................................................................................607 CAN Communication System Description.......................................................................................................................................................................................................................607 Schematic and Routing Diagram..................................................................................................................................................................................................................................608 Body Electrical Control System Wiring Circuit Diagram......................................................................................................................................................................................................608 Component Location.............................................................................................................................................................................................................................................611 BCM and Related System Component Location..................................................................................................................................................................................................................611 Diagnostic Information and Procedures..........................................................................................................................................................................................................................612 BCM Self-Diagnosis Function................................................................................................................................................................................................................................612 Scan Tool Data.............................................................................................................................................................................................................................................613 DTC B1133 (DTC No. 1133): Battery Voltage Too High.........................................................................................................................................................................................................615 DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error)....................................................................................................................................................................................616 DTC U1073 (No. 1073): Control Module Communication Bus Off.................................................................................................................................................................................................618 DTC U1100 (No. 1100): Lost Communication with ECM (Petrol Engine Model with ESP‚)..........................................................................................................................................................................620 DTC U1100 (No. 1100): Lost Communication with ECM (Petrol Engine Model without ESP‚).......................................................................................................................................................................621 DTC U1100 (No. 1100): Lost Communication with ECM (Diesel Engine Model)....................................................................................................................................................................................623 DTC U1101 (No. 1101): Lost Communication with TCM..........................................................................................................................................................................................................624 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module.................................................................................................................................................................................626 Inspection of BCM and its Circuits.........................................................................................................................................................................................................................627 Immobilizer Control System.........................................................................................................................................................................................................................................636 For Petrol Engine Model........................................................................................................................................................................................................................................636 Precautions................................................................................................................................................................................................................................................636 Precautions in Diagnosing Troubles.....................................................................................................................................................................................................................636 Schematic and Routing Diagram..............................................................................................................................................................................................................................637 Immobilizer Control System Wiring Circuit Diagram......................................................................................................................................................................................................637 Diagnostic Information and Procedures......................................................................................................................................................................................................................639 Immobilizer Control System Check.......................................................................................................................................................................................................................639 Diagnostic Trouble Code (DTC) Table....................................................................................................................................................................................................................639 DTC P1614: Transponder Response Error..................................................................................................................................................................................................................640 DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only)...............................................................................................................................................................641 DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only)...........................................................................................................................................................642 DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)................................................................................................................643 DTC P1621: Immobilizer Communication Line Error........................................................................................................................................................................................................644 DTC P1622: EEPROM Error................................................................................................................................................................................................................................645 DTC P1623: Unregistered Transponder....................................................................................................................................................................................................................645 DTC P1625: Immobilizer Antenna Error...................................................................................................................................................................................................................646 DTC P1636: Immobilizer Information Registration Failure................................................................................................................................................................................................646 DTC P1638: Immobilizer Information Mismatched..........................................................................................................................................................................................................647 Keyless Start System...............................................................................................................................................................................................................................................649 General Description............................................................................................................................................................................................................................................649 CAN Communication of Keyless Start System..................................................................................................................................................................................................................649 Schematic and Routing Diagram..................................................................................................................................................................................................................................650 Keyless Start System Electric Wiring Circuit Diagram.......................................................................................................................................................................................................650 Diagnostic Information and Procedures..........................................................................................................................................................................................................................651 Precautions in Diagnosing Troubles.........................................................................................................................................................................................................................651 DTC No. 31: Lost Communication with BCM....................................................................................................................................................................................................................652 DTC No. 33: Control Module Communication Bus Off...........................................................................................................................................................................................................655 COPYRIGHT..............................................................................................................................................................................................................................................................657
S.S
