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Suzuki Swift RS413 RS415 Service Manual – PDF DOWNLOAD
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Description
Suzuki Swift RS413 RS415 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Suzuki Swift RS413 RS415 Service Manual – PDF DOWNLOAD
Language : English
Pages : 1582
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki Swift RS413 RS415 Service Manual – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
- VOLUME 2 contains Transmmision/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10).
Applicable model:
SWIFT (RS413 /RS415) vehicles on and after following vehicle identification numbers (VINs). - The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work.
- Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki Swift RS413 RS415 Service Manual – PDF DOWNLOAD
START.................................................................................................................................................................................................................................... 1 IMPORTANT................................................................................................................................................................................................................................ 1 FOREWORD................................................................................................................................................................................................................................. 3 TABLE OF CONTENTS........................................................................................................................................................................................................................ 5 Precautions.............................................................................................................................................................................................................................. 7 Precautions.......................................................................................................................................................................................................................... 8 Precautions...................................................................................................................................................................................................................... 8 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System............................................................................................................................................. 8 General Precautions.......................................................................................................................................................................................................... 10 Warning for Wheel (with tire) Removal........................................................................................................................................................................................ 13 Precautions for Catalytic Converter.......................................................................................................................................................................................... 13 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 13 Precaution for CAN Communication System...................................................................................................................................................................................... 14 Precautions for Electrical Circuit Service................................................................................................................................................................................... 14 Air Bag Warning.............................................................................................................................................................................................................. 16 Air Bag System Service Warning............................................................................................................................................................................................... 16 Fastener Caution............................................................................................................................................................................................................. 16 Suspension Caution........................................................................................................................................................................................................... 16 Wheels and Tires Caution..................................................................................................................................................................................................... 16 Brake Caution................................................................................................................................................................................................................ 17 Repair Instructions.............................................................................................................................................................................................................. 17 Electrical Circuit Inspection Procedure...................................................................................................................................................................................... 17 Intermittent and Poor Connection Inspection.................................................................................................................................................................................. 19 General Information...................................................................................................................................................................................................................... 21 General Information.................................................................................................................................................................................................................. 22 General Description.............................................................................................................................................................................................................. 22 Abbreviations................................................................................................................................................................................................................ 22 Symbols...................................................................................................................................................................................................................... 23 Wire Color Symbols........................................................................................................................................................................................................... 23 Fasteners Information........................................................................................................................................................................................................ 24 Vehicle Lifting Points....................................................................................................................................................................................................... 26 Engine Supporting Points..................................................................................................................................................................................................... 27 Vehicle Identification Number................................................................................................................................................................................................ 28 Engine Identification Number................................................................................................................................................................................................. 28 Transmission Identification Number........................................................................................................................................................................................... 28 Component Location............................................................................................................................................................................................................... 29 Warning, Caution and Information Labels Location............................................................................................................................................................................. 29 Maintenance and Lubrication.......................................................................................................................................................................................................... 31 Precautions...................................................................................................................................................................................................................... 31 Precautions for Maintenance and Lubrication.................................................................................................................................................................................. 31 Scheduled Maintenance............................................................................................................................................................................................................ 31 Maintenance Schedule under Normal Driving Conditions......................................................................................................................................................................... 31 Maintenance Recommended under Severe Driving Conditions...................................................................................................................................................................... 32 Repair Instructions.............................................................................................................................................................................................................. 33 Accessory Drive Belt Inspection.............................................................................................................................................................................................. 33 Accessory Drive Belt Replacement............................................................................................................................................................................................. 34 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 34 Engine Oil and Filter Change................................................................................................................................................................................................. 34 Engine Coolant Change........................................................................................................................................................................................................ 35 Exhaust System Inspection.................................................................................................................................................................................................... 36 Spark Plug Replacement....................................................................................................................................................................................................... 36 Air Cleaner Filter Inspection................................................................................................................................................................................................ 36 Air Cleaner Filter Replacement............................................................................................................................................................................................... 36 Fuel Lines and Connections Inspection........................................................................................................................................................................................ 36 Fuel Filter Replacement...................................................................................................................................................................................................... 36 Fuel Tank Inspection......................................................................................................................................................................................................... 37 PCV Valve Inspection......................................................................................................................................................................................................... 37 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 37 Brake Discs and Pads (Front) Inspection...................................................................................................................................................................................... 37 Brake Drums and Shoes (Rear) Inspection...................................................................................................................................................................................... 37 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 38 Brake Fluid Replacement...................................................................................................................................................................................................... 38 Brake Lever and Cable Inspection............................................................................................................................................................................................. 38 Clutch Fluid Inspection...................................................................................................................................................................................................... 38 Tires Inspection............................................................................................................................................................................................................. 39 Wheel Discs Inspection....................................................................................................................................................................................................... 39 Wheel Bearing Inspection..................................................................................................................................................................................................... 39 Suspension System Inspection................................................................................................................................................................................................. 39 Steering System Inspection................................................................................................................................................................................................... 39 Drive Shaft (Axle) Boots Inspection.......................................................................................................................................................................................... 40 Manual Transaxle Oil Inspection.............................................................................................................................................................................................. 40 Manual Transaxle Oil Replacement............................................................................................................................................................................................. 40 Automatic Transaxle Fluid Level Inspection................................................................................................................................................................................... 40 Automatic Transaxle Fluid Replacement........................................................................................................................................................................................ 41 Automatic Transaxle Fluid Cooler Hose Inspection............................................................................................................................................................................. 41 All Latches, Hinges and Locks Inspection..................................................................................................................................................................................... 41 Air Conditioning Filter (If Equipped) Inspection............................................................................................................................................................................. 42 Air Conditioning Filter (If Equipped) Replacement............................................................................................................................................................................ 42 Final Inspection for Maintenance Service..................................................................................................................................................................................... 42 Specifications................................................................................................................................................................................................................... 43 Tightening Torque Specifications............................................................................................................................................................................................. 43 Special Tools and Equipment...................................................................................................................................................................................................... 44 Recommended Fluids and Lubricants............................................................................................................................................................................................ 44 Special Tool................................................................................................................................................................................................................. 44 Engine................................................................................................................................................................................................................................... 45 Precautions.......................................................................................................................................................................................................................... 50 Precautions...................................................................................................................................................................................................................... 50 Precautions for Engine....................................................................................................................................................................................................... 50 Engine General Information and Diagnosis............................................................................................................................................................................................. 51 Precautions...................................................................................................................................................................................................................... 51 Precautions on Engine Service................................................................................................................................................................................................ 51 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 51 Precautions of ECM Circuit Inspection........................................................................................................................................................................................ 52 Precautions of Electric Throttle Body System Calibration (For Automated Manual Transaxle Model).............................................................................................................................. 52 General Description.............................................................................................................................................................................................................. 52 Statement on Cleanliness and Care............................................................................................................................................................................................ 52 Engine Diagnosis General Description......................................................................................................................................................................................... 52 On-Board Diagnostic System Description....................................................................................................................................................................................... 53 Engine and Emission Control System Description............................................................................................................................................................................... 55 CAN Communication System Description......................................................................................................................................................................................... 55 Air Intake System Description................................................................................................................................................................................................ 58 Description of Electric Throttle Body System (For Automated Manual Transaxle Model).......................................................................................................................................... 59 Description of Electric Throttle Body System Calibration (For Automated Manual Transaxle Model).............................................................................................................................. 60 Electronic Control System Description........................................................................................................................................................................................ 60 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 67 Schematic and Routing Diagram.................................................................................................................................................................................................... 68 Engine and Emission Control System Diagram................................................................................................................................................................................... 68 Component Location............................................................................................................................................................................................................... 69 Electronic Control System Components Location................................................................................................................................................................................ 69 Diagnostic Information and Procedures............................................................................................................................................................................................ 70 Engine and Emission Control System Check..................................................................................................................................................................................... 70 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 73 DTC Check.................................................................................................................................................................................................................... 73 DTC Clearance................................................................................................................................................................................................................ 74 DTC Table.................................................................................................................................................................................................................... 74 Fail-Safe Table.............................................................................................................................................................................................................. 80 Scan Tool Data............................................................................................................................................................................................................... 82 Visual Inspection............................................................................................................................................................................................................ 88 Engine Basic Inspection...................................................................................................................................................................................................... 88 Engine Symptom Diagnosis..................................................................................................................................................................................................... 91 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started).............................................................................................................. 99 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 101 DTC P0010: Camshaft Position Actuator Circuit (For M15 Engine Model)......................................................................................................................................................... 103 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For M15 Engine Model)......................................................................................................... 105 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 107 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 109 DTC P0101: Mass Air Flow Circuit Range / Performance......................................................................................................................................................................... 111 DTC P0102: Mass Air Flow Circuit Low Input................................................................................................................................................................................... 115 DTC P0103: Mass Air Flow Circuit High Input.................................................................................................................................................................................. 117 DTC P0106: Manifold Absolute Pressure Range / Performance.................................................................................................................................................................... 119 DTC P0107: Manifold Absolute Pressure Circuit Low Input...................................................................................................................................................................... 122 DTC P0108: Manifold Absolute Pressure Circuit High Input..................................................................................................................................................................... 124 DTC P0111: Intake Air Temperature Circuit Range / Performance................................................................................................................................................................ 126 DTC P0112: Intake Air Temperature Sensor Circuit Low......................................................................................................................................................................... 129 DTC P0113: Intake Air Temperature Sensor Circuit High........................................................................................................................................................................ 132 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 134 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 137 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 139 DTC P0121: Throttle Position Sensor Circuit Range / Performance (For A/T and M/T Models)..................................................................................................................................... 142 DTC P0122: Throttle Position Sensor Circuit Low (For A/T and M/T Models)..................................................................................................................................................... 146 DTC P0122: Throttle Position Sensor (Main) Circuit Low (For Automated Manual Transaxle Model)................................................................................................................................ 149 DTC P0123: Throttle Position Sensor Circuit High (For A/T and M/T Models).................................................................................................................................................... 152 DTC P0123: Throttle Position Sensor (Main) Circuit High (For Automated Manual Transaxle Model)............................................................................................................................... 155 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................................................................................................ 158 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 161 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).......................................................................................................................................................... 162 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 165 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 168 DTC P0171 / P0172: Fuel System Too Lean / Rich............................................................................................................................................................................... 170 DTC P0222: Throttle Position Sensor (Sub) Circuit Low (For Automated Manual Transaxle Model)................................................................................................................................. 172 DTC P0223: Throttle Position Sensor (Sub) Circuit High (For Automated Manual Transaxle Model)................................................................................................................................ 175 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...................................................................................... 178 DTC P0327 / P0328: Knock Sensor Circuit Low / High........................................................................................................................................................................... 180 DTC P0335: Crankshaft Position (CKP) Sensor Circuit.......................................................................................................................................................................... 182 DTC P0340: Camshaft Position (CMP) Sensor Circuit............................................................................................................................................................................ 184 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 187 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 190 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 192 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 194 DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High...................................................................................................................................................................... 196 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 197 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction............................................................................................................................................................................ 201 DTC P0505: Idle Air Control System (For A/T and M/T models).................................................................................................................................................................. 204 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low....................................................................................................................................................................... 206 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...................................................................................................................................................................... 208 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance (For Automated Manual Transaxle Model)............................................. 210 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 211 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 212 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 214 DTC P1603: TCM Trouble Code Detected......................................................................................................................................................................................... 215 DTC P1674: CAN Communication (Bus Off Error)................................................................................................................................................................................. 216 DTC P1675: CAN Communication (Transmission Error)............................................................................................................................................................................ 222 DTC P1676: CAN Communication (Reception Error for TCM (for A/T or Automated Manual Transaxle model))......................................................................................................................... 227 DTC P1678: CAN Communication (Reception Error for BCM)....................................................................................................................................................................... 230 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance (For Automated Manual Transaxle Model)................................................................................................................ 233 DTC P2102: Throttle Actuator Control Motor Circuit Low (For Automated Manual Transaxle Model)................................................................................................................................ 235 DTC P2103: Throttle Actuator Control Motor Circuit High (For Automated Manual Transaxle Model)............................................................................................................................... 237 DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed (For Automated Manual Transaxle Model)............................................................................................................. 239 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance (For Automated Manual Transaxle Model)................................................................................................................ 240 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input (For Automated Manual Transaxle Model)............................................................................................................................. 243 DTC P2123: Pedal Position Sensor (Main) Circuit High Input (For Automated Manual Transaxle Model)............................................................................................................................ 246 DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input (For Automated Manual Transaxle Model).............................................................................................................................. 249 DTC P2128: Pedal Position Sensor (Sub) Circuit High Input (For Automated Manual Transaxle Model)............................................................................................................................. 252 DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation (For Automated Manual Transaxle Model).................................................................................................................. 255 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation (For Automated Manual Transaxle Model)..................................................................................................................... 258 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 260 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 261 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 287 Fuel Injector Circuit Check.................................................................................................................................................................................................. 290 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 292 Fuel Pressure Check.......................................................................................................................................................................................................... 295 Idle Air Control System Check (For A/T and M/T models)....................................................................................................................................................................... 296 A/C System Circuits Check.................................................................................................................................................................................................... 298 Electric Load Signal Circuit Check........................................................................................................................................................................................... 301 Radiator cooling fan Low Speed Control System Check.......................................................................................................................................................................... 303 Radiator cooling fan High Speed Control System Check......................................................................................................................................................................... 305 Repair Instructions.............................................................................................................................................................................................................. 308 Idle Speed / Idle Air Control (IAC) Duty Inspection (For A/T and M/T Models)................................................................................................................................................. 308 Special Tools and Equipment...................................................................................................................................................................................................... 308 Special Tool................................................................................................................................................................................................................. 308 Aux. Emission Control Devices........................................................................................................................................................................................................ 310 Diagnostic Information and Procedures............................................................................................................................................................................................ 310 EGR System Inspection........................................................................................................................................................................................................ 310 Repair Instructions.............................................................................................................................................................................................................. 310 EVAP Canister Purge Inspection............................................................................................................................................................................................... 310 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 310 Vacuum Passage Inspection.................................................................................................................................................................................................... 311 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................................................................................................... 311 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 312 EVAP Canister Inspection..................................................................................................................................................................................................... 312 EGR Valve Removal and Installation........................................................................................................................................................................................... 313 EGR Valve Inspection......................................................................................................................................................................................................... 313 PCV Hose Inspection.......................................................................................................................................................................................................... 313 PCV Valve Inspection......................................................................................................................................................................................................... 313 Special Tools and Equipment...................................................................................................................................................................................................... 314 Special Tool................................................................................................................................................................................................................. 314 Engine Electrical Devices............................................................................................................................................................................................................ 315 Repair Instructions.............................................................................................................................................................................................................. 315 Idle Air Control (IAC) Valve Operation Inspection (For A/T and M/T Models)................................................................................................................................................... 315 Idle Air Control (IAC) Valve On-Vehicle Inspection (For A/T and M/T Models).................................................................................................................................................. 315 Idle Air Control (IAC) Valve Removal and Installation (For A/T and M/T Models)............................................................................................................................................... 315 Engine Control Module (ECM) Removal and Installation......................................................................................................................................................................... 316 Manifold Absolute Pressure (MAP) Sensor Inspection........................................................................................................................................................................... 316 Throttle Position (TP) Sensor On-Vehicle Inspection (For A/T and M/T Models)................................................................................................................................................. 317 Throttle Position (TP) Sensor Removal and Installation (For A/T and M/T Models).............................................................................................................................................. 317 Electric Throttle Body Assembly On-Vehicle Inspection (For Automated Manual Transaxle Model)................................................................................................................................. 318 Electric Throttle Body System Calibration (For Automated Manual Transaxle Model)............................................................................................................................................. 320 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection (For Automated Manual Transaxle Model)................................................................................................................ 320 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation (For Automated Manual Transaxle Model)............................................................................................................. 321 Accelerator Pedal Position (APP) Sensor Assembly Inspection (For Automated Manual Transaxle Model)........................................................................................................................... 321 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................................................................................................................. 322 Engine Coolant Temperature (ECT) Sensor Inspection........................................................................................................................................................................... 322 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection........................................................................................................................................................ 323 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation............................................................................................................................................................ 323 Camshaft Position (CMP) Sensor Removal and Installation...................................................................................................................................................................... 323 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 324 Crankshaft Position (CKP) Sensor Removal and Installation.................................................................................................................................................................... 324 Crankshaft Position (CKP) Sensor Inspection.................................................................................................................................................................................. 325 Vehicle Speed Sensor (VSS) Inspection (M/T and Automated Manual Transaxle model)............................................................................................................................................. 325 Knock Sensor Removal and Installation........................................................................................................................................................................................ 326 Main Relay, Fuel Pump Relay, Starting Motor Control Relay and Throttle Actuator Control Relay Inspection..................................................................................................................... 326 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................................................................................................ 326 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation......................................................................................................................................... 327 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection....................................................................................................................................................... 328 Specifications................................................................................................................................................................................................................... 329 Tightening Torque Specifications............................................................................................................................................................................................. 329 Special Tools and Equipment...................................................................................................................................................................................................... 329 Special Tool................................................................................................................................................................................................................. 329 Engine Mechanical.................................................................................................................................................................................................................... 330 General Description.............................................................................................................................................................................................................. 330 Engine Construction Description.............................................................................................................................................................................................. 330 Camshaft Position Control (VVT Variable Valve Timing) System Description..................................................................................................................................................... 331 Diagnostic Information and Procedures............................................................................................................................................................................................ 334 Compression Check............................................................................................................................................................................................................ 334 Engine Vacuum Check.......................................................................................................................................................................................................... 335 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 335 Repair Instructions.............................................................................................................................................................................................................. 338 Air Cleaner Element Removal and Installation................................................................................................................................................................................. 338 Air Cleaner Element Inspection and Cleaning.................................................................................................................................................................................. 338 Cylinder Head Cover Removal and Installation................................................................................................................................................................................. 338 Accelerator Cable Adjustment (For A/T and M/T Models)........................................................................................................................................................................ 340 Throttle Body Components..................................................................................................................................................................................................... 341 Throttle Body On-Vehicle Inspection.......................................................................................................................................................................................... 341 Throttle Body Removal and Installation (For A/T and M/T Models).............................................................................................................................................................. 341 Electric Throttle Body Assembly Removal and Installation (For Automated Manual Transaxle Model).............................................................................................................................. 342 Throttle Body Cleaning....................................................................................................................................................................................................... 343 Throttle Body and Intake Manifold Components................................................................................................................................................................................. 344 Intake Manifold Removal and Installation..................................................................................................................................................................................... 344 Engine Mountings Components.................................................................................................................................................................................................. 346 Engine Assembly Removal and Installation..................................................................................................................................................................................... 347 Timing Chain Cover Components................................................................................................................................................................................................ 351 Timing Chain Cover Removal and Installation.................................................................................................................................................................................. 352 Timing Chain Cover Inspection................................................................................................................................................................................................ 354 Oil Control Valve Removal and Installation (For Engine with VVT)............................................................................................................................................................. 354 Oil Control Valve Inspection (For Engine with VVT)........................................................................................................................................................................... 355 Timing Chain and Chain Tensioner Components.................................................................................................................................................................................. 355 Timing Chain and Chain Tensioner Removal and Installation.................................................................................................................................................................... 356 Timing Chain and Chain Tensioner Inspection.................................................................................................................................................................................. 359 Camshaft, Tappet and Shim Components......................................................................................................................................................................................... 361 Camshaft, Tappet and Shim Removal and Installation........................................................................................................................................................................... 362 Camshaft, Tappet and Shim Inspection......................................................................................................................................................................................... 364 Valves and Cylinder Head Components.......................................................................................................................................................................................... 367 Valves and Cylinder Head Removal and Installation............................................................................................................................................................................ 367 Valves and Cylinder Head Disassembly and Assembly............................................................................................................................................................................ 369 Valves and Valve Guides Inspection........................................................................................................................................................................................... 372 Cylinder Head Inspection..................................................................................................................................................................................................... 374 Valve Spring Inspection...................................................................................................................................................................................................... 375 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................................................................................................. 376 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................................................................................................ 376 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................................................................................................ 377 Cylinders, Pistons and Piston Rings Inspection............................................................................................................................................................................... 378 Piston Pins and Connecting Rods Inspection................................................................................................................................................................................... 380 Crank Pin and Connecting Rod Bearings Inspection............................................................................................................................................................................. 381 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................................................................................................... 385 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................................................................................................ 386 Crankshaft Inspection........................................................................................................................................................................................................ 388 Main Bearings Inspection..................................................................................................................................................................................................... 389 Sensor Plate Inspection...................................................................................................................................................................................................... 395 Rear Oil Seal Inspection..................................................................................................................................................................................................... 395 Flywheel Inspection.......................................................................................................................................................................................................... 395 Cylinder Block Inspection.................................................................................................................................................................................................... 395 Specifications................................................................................................................................................................................................................... 396 Tightening Torque Specifications............................................................................................................................................................................................. 396 Special Tools and Equipment...................................................................................................................................................................................................... 397 Recommended Service Material................................................................................................................................................................................................. 397 Special Tool................................................................................................................................................................................................................. 397 Engine Lubrication System............................................................................................................................................................................................................ 399 General Description.............................................................................................................................................................................................................. 399 Engine Lubrication Description............................................................................................................................................................................................... 399 Diagnostic Information and Procedures............................................................................................................................................................................................ 401 Oil Pressure Check........................................................................................................................................................................................................... 401 Repair Instructions.............................................................................................................................................................................................................. 402 Oil Pan and Oil Pump Strainer Components..................................................................................................................................................................................... 402 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................................................................................................... 403 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................................................................................................... 404 Oil Pump Components.......................................................................................................................................................................................................... 405 Oil Pump Removal and Installation............................................................................................................................................................................................ 405 Oil Pump Disassembly and Reassembly.......................................................................................................................................................................................... 405 Oil Pump Inspection.......................................................................................................................................................................................................... 406 Specifications................................................................................................................................................................................................................... 407 Tightening Torque Specifications............................................................................................................................................................................................. 407 Special Tools and Equipment...................................................................................................................................................................................................... 408 Recommended Service Material................................................................................................................................................................................................. 408 Special Tool................................................................................................................................................................................................................. 408 Engine Cooling System................................................................................................................................................................................................................ 409 General Description.............................................................................................................................................................................................................. 409 Cooling System Description................................................................................................................................................................................................... 409 Coolant Description.......................................................................................................................................................................................................... 409 Schematic and Routing Diagram.................................................................................................................................................................................................... 410 Coolant Circulation.......................................................................................................................................................................................................... 410 Diagnostic Information and Procedures............................................................................................................................................................................................ 411 Engine Cooling Symptom Diagnosis............................................................................................................................................................................................. 411 Repair Instructions.............................................................................................................................................................................................................. 412 Cooling System Components.................................................................................................................................................................................................... 412 Coolant Level Check.......................................................................................................................................................................................................... 413 Engine Cooling System Inspection and Cleaning................................................................................................................................................................................ 413 Cooling System Draining...................................................................................................................................................................................................... 413 Cooling System Flush and Refill.............................................................................................................................................................................................. 414 Cooling Water Pipes or Hoses Removal and Installation........................................................................................................................................................................ 415 Thermostat Removal and Installation.......................................................................................................................................................................................... 415 Thermostat Inspection........................................................................................................................................................................................................ 415 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................................................................................................................. 416 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 416 Radiator Cooling Fan Removal and Installation................................................................................................................................................................................ 416 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 417 Radiator Removal and Installation............................................................................................................................................................................................ 417 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.......................................................................................................................................................... 417 Water Pump / Generator Drive Belt Removal and Installation................................................................................................................................................................... 418 Water Pump Removal and Installation.......................................................................................................................................................................................... 419 Water Pump Inspection........................................................................................................................................................................................................ 419 Specifications................................................................................................................................................................................................................... 420 Tightening Torque Specifications............................................................................................................................................................................................. 420 Special Tools and Equipment...................................................................................................................................................................................................... 420 Recommended Service Material................................................................................................................................................................................................. 420 Fuel System.......................................................................................................................................................................................................................... 421 Precautions...................................................................................................................................................................................................................... 421 Precautions on Fuel System Service........................................................................................................................................................................................... 421 General Description.............................................................................................................................................................................................................. 421 Fuel System Description...................................................................................................................................................................................................... 421 Fuel Delivery System Description............................................................................................................................................................................................. 421 Fuel Pump Description........................................................................................................................................................................................................ 422 Schematic and Routing Diagram.................................................................................................................................................................................................... 422 Fuel Delivery System Diagram................................................................................................................................................................................................. 422 Diagnostic Information and Procedures............................................................................................................................................................................................ 422 Fuel Pressure Inspection..................................................................................................................................................................................................... 422 Fuel Cut Operation Inspection................................................................................................................................................................................................ 423 Repair Instructions.............................................................................................................................................................................................................. 424 Fuel System Components....................................................................................................................................................................................................... 424 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 425 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 427 Fuel Leakage Check Procedure................................................................................................................................................................................................. 427 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 427 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 427 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 428 Fuel Injector Removal and Installation....................................................................................................................................................................................... 428 Fuel Injector Inspection..................................................................................................................................................................................................... 429 Fuel Filler Cap Inspection................................................................................................................................................................................................... 430 Fuel Tank Removal and Installation........................................................................................................................................................................................... 430 Fuel Tank Inspection......................................................................................................................................................................................................... 432 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 432 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 432 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 433 Fuel Pump Inspection......................................................................................................................................................................................................... 434 Specifications................................................................................................................................................................................................................... 435 Tightening Torque Specifications............................................................................................................................................................................................. 435 Special Tools and Equipment...................................................................................................................................................................................................... 435 Special Tool................................................................................................................................................................................................................. 435 Ignition System...................................................................................................................................................................................................................... 437 General Description.............................................................................................................................................................................................................. 437 Ignition System Construction................................................................................................................................................................................................. 437 Schematic and Routing Diagram.................................................................................................................................................................................................... 438 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 438 Component Location............................................................................................................................................................................................................... 439 Ignition System Components Location.......................................................................................................................................................................................... 439 Diagnostic Information and Procedures............................................................................................................................................................................................ 439 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 439 Reference Waveform of Ignition System........................................................................................................................................................................................ 440 Ignition System Check........................................................................................................................................................................................................ 440 Ignition Spark Test.......................................................................................................................................................................................................... 441 Repair Instructions.............................................................................................................................................................................................................. 442 High-Tension Cord Removal and Installation................................................................................................................................................................................... 442 High-Tension Cord Inspection................................................................................................................................................................................................. 442 Spark Plug Removal and Installation.......................................................................................................................................................................................... 442 Spark Plug Inspection........................................................................................................................................................................................................ 443 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................................................................................................... 443 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................................................................................................ 444 Ignition Timing Inspection................................................................................................................................................................................................... 444 Specifications................................................................................................................................................................................................................... 445 Tightening Torque Specifications............................................................................................................................................................................................. 445 Special Tools and Equipment...................................................................................................................................................................................................... 445 Special Tool................................................................................................................................................................................................................. 445 Starting System...................................................................................................................................................................................................................... 446 Schematic and Routing Diagram.................................................................................................................................................................................................... 446 Cranking System Circuit Diagram.............................................................................................................................................................................................. 446 Diagnostic Information and Procedures............................................................................................................................................................................................ 446 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 446 Cranking System Test......................................................................................................................................................................................................... 448 Repair Instructions.............................................................................................................................................................................................................. 449 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 449 Starting Motor Components.................................................................................................................................................................................................... 450 Starting Motor Inspection.................................................................................................................................................................................................... 452 Specifications................................................................................................................................................................................................................... 455 Cranking System Specifications............................................................................................................................................................................................... 455 Tightening Torque Specifications............................................................................................................................................................................................. 456 Special Tools and Equipment...................................................................................................................................................................................................... 456 Recommended Service Material................................................................................................................................................................................................. 456 Charging System...................................................................................................................................................................................................................... 457 General Description.............................................................................................................................................................................................................. 457 Battery Description.......................................................................................................................................................................................................... 457 Generator Description........................................................................................................................................................................................................ 458 Diagnostic Information and Procedures............................................................................................................................................................................................ 459 Battery Inspection........................................................................................................................................................................................................... 459 Generator Symptom Diagnosis.................................................................................................................................................................................................. 459 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 460 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 460 Repair Instructions.............................................................................................................................................................................................................. 461 Jump Starting in Case of Emergency........................................................................................................................................................................................... 461 Battery Dismounting and Remounting........................................................................................................................................................................................... 461 Generator Dismounting and Remounting......................................................................................................................................................................................... 462 Generator Components......................................................................................................................................................................................................... 462 Generator Inspection......................................................................................................................................................................................................... 463 Specifications................................................................................................................................................................................................................... 464 Charging System Specifications............................................................................................................................................................................................... 464 Tightening Torque Specifications............................................................................................................................................................................................. 465 Exhaust System....................................................................................................................................................................................................................... 466 General Description.............................................................................................................................................................................................................. 466 Exhaust System Description................................................................................................................................................................................................... 466 Diagnostic Information and Procedures............................................................................................................................................................................................ 466 Exhaust System Check......................................................................................................................................................................................................... 466 Repair Instructions.............................................................................................................................................................................................................. 467 Exhaust System Components.................................................................................................................................................................................................... 467 Exhaust Manifold Removal and Installation.................................................................................................................................................................................... 468 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 469 Specifications................................................................................................................................................................................................................... 470 Tightening Torque Specifications............................................................................................................................................................................................. 470 Suspension............................................................................................................................................................................................................................... 471 Precautions.......................................................................................................................................................................................................................... 473 Precautions...................................................................................................................................................................................................................... 473 Precautions on Suspension.................................................................................................................................................................................................... 473 Suspension General Diagnosis......................................................................................................................................................................................................... 474 Diagnostic Information and Procedures............................................................................................................................................................................................ 474 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 474 Specifications................................................................................................................................................................................................................... 476 Wheel Alignment Specifications............................................................................................................................................................................................... 476 Front Suspension..................................................................................................................................................................................................................... 477 General Description.............................................................................................................................................................................................................. 477 Front Suspension Construction................................................................................................................................................................................................ 477 Front Wheel Alignment Construction........................................................................................................................................................................................... 478 Repair Instructions.............................................................................................................................................................................................................. 478 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 478 Front Strut Assembly Components.............................................................................................................................................................................................. 480 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 480 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 482 Front Strut Assembly Check................................................................................................................................................................................................... 483 Front Wheel Hub and Steering Knuckle Components.............................................................................................................................................................................. 484 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................................................................................................. 484 Front Wheel Hub, Disc, Nut and Bearing Check................................................................................................................................................................................. 488 Suspension Control Arm / Bushing Removal and Installation.................................................................................................................................................................... 488 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 489 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 490 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 490 Suspension Control Arm Joint Check........................................................................................................................................................................................... 490 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 491 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 491 Front Suspension Frame Check................................................................................................................................................................................................. 494 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 495 Front Suspension Fasteners Check............................................................................................................................................................................................. 495 Specifications................................................................................................................................................................................................................... 495 Tightening Torque Specifications............................................................................................................................................................................................. 495 Special Tools and Equipment...................................................................................................................................................................................................... 496 Special Tool................................................................................................................................................................................................................. 496 Rear Suspension...................................................................................................................................................................................................................... 498 General Description.............................................................................................................................................................................................................. 498 Rear Suspension Construction................................................................................................................................................................................................. 498 Repair Instructions.............................................................................................................................................................................................................. 499 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 499 Rear Shock Absorber Inspection............................................................................................................................................................................................... 500 Rear Shock Absorber Bush Removal and Installation............................................................................................................................................................................ 500 Rear Shock Absorber Bush Inspection.......................................................................................................................................................................................... 501 Coil Spring Removal and Installation......................................................................................................................................................................................... 501 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................................................................................................. 502 Spring Upper Seat and Lower Seat Removal and Installation.................................................................................................................................................................... 502 Rear Axle Removal and Installation........................................................................................................................................................................................... 503 Trailing Arm, Rear Axle and Coil Spring Inspection........................................................................................................................................................................... 506 Rear Axle Bush Inspection.................................................................................................................................................................................................... 506 Wheel Bearing and Wheel Stud Bolt Removal and Installation................................................................................................................................................................... 507 Rear Wheel Disc, Nut and Bearing Inspection.................................................................................................................................................................................. 507 Spindle Removal and Installation............................................................................................................................................................................................. 508 Spindle Inspection........................................................................................................................................................................................................... 509 Rear Suspension Fasteners Inspection......................................................................................................................................................................................... 509 Specifications................................................................................................................................................................................................................... 510 Tightening Torque Specifications............................................................................................................................................................................................. 510 Special Tools and Equipment...................................................................................................................................................................................................... 510 Special Tool................................................................................................................................................................................................................. 510 Wheels and Tires..................................................................................................................................................................................................................... 511 General Description.............................................................................................................................................................................................................. 511 Tires Description............................................................................................................................................................................................................ 511 Wheels Description........................................................................................................................................................................................................... 512 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 512 Wear Indicators Description.................................................................................................................................................................................................. 513 Radial Tire Waddle Description............................................................................................................................................................................................... 513 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 514 Balancing Wheels Description................................................................................................................................................................................................. 514 Repair Instructions.............................................................................................................................................................................................................. 515 General Balance Procedures................................................................................................................................................................................................... 515 Tire Rotation................................................................................................................................................................................................................ 515 Wheel Removal and Installation............................................................................................................................................................................................... 515 Tire Mounting and Dismounting................................................................................................................................................................................................ 516 Tire Repair.................................................................................................................................................................................................................. 516 Specifications................................................................................................................................................................................................................... 517 Wheels and Tires Specifications.............................................................................................................................................................................................. 517 Tightening Torque Specifications............................................................................................................................................................................................. 517 Driveline / Axle......................................................................................................................................................................................................................... 519 Precautions.......................................................................................................................................................................................................................... 520 Precautions...................................................................................................................................................................................................................... 520 Precautions for Driveline / Axle............................................................................................................................................................................................. 520 Drive Shaft / Axle................................................................................................................................................................................................................... 521 General Description.............................................................................................................................................................................................................. 521 Front Drive Shaft Construction............................................................................................................................................................................................... 521 Component Location............................................................................................................................................................................................................... 521 Front Drive Shaft Assembly Components Location............................................................................................................................................................................... 521 Diagnostic Information and Procedures............................................................................................................................................................................................ 522 Front Drive Shaft Symptom Diagnosis.......................................................................................................................................................................................... 522 Repair Instructions.............................................................................................................................................................................................................. 522 Front Drive Shaft Components................................................................................................................................................................................................. 522 Front Drive Shaft Assembly On-Vehicle Inspection............................................................................................................................................................................. 524 Front Drive Shaft Assembly Removal and Installation.......................................................................................................................................................................... 524 Front Drive Shaft Disassembly and Assembly................................................................................................................................................................................... 525 Center Shaft and Center Bearing Support Disassembly and Assembly............................................................................................................................................................. 528 Front Drive Shaft Inspection................................................................................................................................................................................................. 530 Specifications................................................................................................................................................................................................................... 531 Tightening Torque Specifications............................................................................................................................................................................................. 531 Special Tools and Equipment...................................................................................................................................................................................................... 531 Recommended Service Material................................................................................................................................................................................................. 531 Special Tool................................................................................................................................................................................................................. 531 Brakes................................................................................................................................................................................................................................... 533 Precautions.......................................................................................................................................................................................................................... 535 Precautions...................................................................................................................................................................................................................... 535 Precautions for Brakes....................................................................................................................................................................................................... 535 Brake Control System and Diagnosis................................................................................................................................................................................................... 536 Precautions...................................................................................................................................................................................................................... 536 Precautions on Brake......................................................................................................................................................................................................... 536 General Description.............................................................................................................................................................................................................. 536 Brakes Construction.......................................................................................................................................................................................................... 536 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 537 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 538 Diagnostic Information and Procedures............................................................................................................................................................................................ 538 Brakes Diagnosis Note........................................................................................................................................................................................................ 538 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 539 Repair Instructions.............................................................................................................................................................................................................. 541 Brake Pedal Free Height Inspection........................................................................................................................................................................................... 541 Brake Pedal Play Inspection.................................................................................................................................................................................................. 541 Excessive Pedal Travel Inspection............................................................................................................................................................................................ 541 Master Cylinder and Brake Fluid Level Inspection............................................................................................................................................................................. 542 Stop Light Switch Adjustment................................................................................................................................................................................................. 542 Air Bleeding of Brake System................................................................................................................................................................................................. 542 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 543 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 544 Brake Hose and Pipe Inspection............................................................................................................................................................................................... 544 Master Cylinder Components................................................................................................................................................................................................... 545 Master Cylinder Assembly Removal and Installation............................................................................................................................................................................ 545 Master Cylinder Reservoir Removal and Installation........................................................................................................................................................................... 547 Master Cylinder Assembly Inspection.......................................................................................................................................................................................... 548 Brake Booster Components..................................................................................................................................................................................................... 548 Booster Operation Inspection................................................................................................................................................................................................. 548 Brake Booster Removal and Installation....................................................................................................................................................................................... 549 Brake Booster Inspection..................................................................................................................................................................................................... 550 Specifications................................................................................................................................................................................................................... 551 Tightening Torque Specifications............................................................................................................................................................................................. 551 Special Tools and Equipment...................................................................................................................................................................................................... 551 Recommended Service Material................................................................................................................................................................................................. 551 Front Brakes......................................................................................................................................................................................................................... 552 Repair Instructions.............................................................................................................................................................................................................. 552 Front Disc Brake Components.................................................................................................................................................................................................. 552 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................... 552 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 553 Front Disc Brake Pad Inspection.............................................................................................................................................................................................. 554 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 554 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 555 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 557 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 557 Front Brake Disc Inspection.................................................................................................................................................................................................. 558 Specifications................................................................................................................................................................................................................... 558 Tightening Torque Specifications............................................................................................................................................................................................. 558 Special Tools and Equipment...................................................................................................................................................................................................... 559 Recommended Service Material................................................................................................................................................................................................. 559 Special Tool................................................................................................................................................................................................................. 559 Rear Brakes.......................................................................................................................................................................................................................... 560 Repair Instructions.............................................................................................................................................................................................................. 560 Rear Drum Brake Components................................................................................................................................................................................................... 560 Rear Brake Drum Removal and Installation..................................................................................................................................................................................... 560 Rear Brake Drum and Shoe Inspection.......................................................................................................................................................................................... 562 Rear Brake Shoe On-Vehicle Inspection........................................................................................................................................................................................ 562 ABS Sensor Ring Removal and Installation (If Equipped)....................................................................................................................................................................... 563 ABS Sensor Ring Inspection................................................................................................................................................................................................... 563 Rear Brake Shoe Removal and Installation..................................................................................................................................................................................... 563 Rear Brake Shoe Inspection................................................................................................................................................................................................... 564 Wheel Cylinder Removal and Installation...................................................................................................................................................................................... 564 Wheel Cylinder Inspection.................................................................................................................................................................................................... 565 Brake Back Plate Removal and Installation.................................................................................................................................................................................... 565 Specifications................................................................................................................................................................................................................... 567 Tightening Torque Specifications............................................................................................................................................................................................. 567 Special Tools and Equipment...................................................................................................................................................................................................... 567 Recommended Service Material................................................................................................................................................................................................. 567 Special Tool................................................................................................................................................................................................................. 567 Parking Brake........................................................................................................................................................................................................................ 568 General Description.............................................................................................................................................................................................................. 568 Parking Brake Cable Construction............................................................................................................................................................................................. 568 Repair Instructions.............................................................................................................................................................................................................. 569 Parking Brake Inspection and Adjustment...................................................................................................................................................................................... 569 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 569 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 570 Specifications................................................................................................................................................................................................................... 571 Tightening Torque Specifications............................................................................................................................................................................................. 571 ABS.................................................................................................................................................................................................................................. 572 Precautions...................................................................................................................................................................................................................... 572 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 572 Precautions in On-Vehicle Service............................................................................................................................................................................................ 572 General Description.............................................................................................................................................................................................................. 572 ABS Description.............................................................................................................................................................................................................. 572 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 573 Schematic and Routing Diagram.................................................................................................................................................................................................... 574 ABS Schematic................................................................................................................................................................................................................ 574 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 575 Component Location............................................................................................................................................................................................................... 576 ABS Components Location...................................................................................................................................................................................................... 576 Diagnostic Information and Procedures............................................................................................................................................................................................ 577 ABS Check.................................................................................................................................................................................................................... 577 ABS Warning Lamp Check....................................................................................................................................................................................................... 579 EBD Warning Lamp (Brake Warning Lamp) Check.................................................................................................................................................................................. 579 DTC Check.................................................................................................................................................................................................................... 579 DTC Table.................................................................................................................................................................................................................... 580 DTC Clearance................................................................................................................................................................................................................ 580 Scan Tool Data............................................................................................................................................................................................................... 580 ABS Warning Lamp Does Not Come ON at Ignition Switch ON...................................................................................................................................................................... 581 ABS Warning Lamp Comes ON Steady............................................................................................................................................................................................. 582 ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON............................................................................................................................................................ 584 EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady........................................................................................................................................................................ 584 Serial Data Link Circuit Check............................................................................................................................................................................................... 585 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring.................................................................. 587 DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit.... 589 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 590 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 591 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 592 DTC C1071: ABS Control Module................................................................................................................................................................................................ 593 Repair Instructions.............................................................................................................................................................................................................. 594 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 594 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 595 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 595 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 595 Front Wheel Speed Sensor On-Vehicle Inspection............................................................................................................................................................................... 597 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 597 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 598 Rear Wheel Speed Sensor On-Vehicle Inspection................................................................................................................................................................................ 598 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 599 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 600 Front Wheel Speed Sensor Ring On-Vehicle Inspection.......................................................................................................................................................................... 600 Front Wheel Speed Sensor Ring Removal and Installation....................................................................................................................................................................... 600 Rear Wheel Speed Sensor Ring On-Vehicle Inspection........................................................................................................................................................................... 600 Rear Wheel Speed Sensor Ring Removal and Installation........................................................................................................................................................................ 601 Specifications................................................................................................................................................................................................................... 601 Tightening Torque Specifications............................................................................................................................................................................................. 601 Special Tools and Equipment...................................................................................................................................................................................................... 601 Special Tool................................................................................................................................................................................................................. 601 Transmission / Transaxle................................................................................................................................................................................................................. 603 Precautions.......................................................................................................................................................................................................................... 608 Precautions...................................................................................................................................................................................................................... 608 Precautions on Transmission / Transaxle...................................................................................................................................................................................... 608 Automatic Transmission............................................................................................................................................................................................................... 609 Precautions...................................................................................................................................................................................................................... 609 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 609 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 609 General Description.............................................................................................................................................................................................................. 611 A/T Description.............................................................................................................................................................................................................. 611 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................................................................................................. 613 Table of Component Operation................................................................................................................................................................................................. 614 A/T Diagnosis General Description............................................................................................................................................................................................ 614 On-Board Diagnostic System Description....................................................................................................................................................................................... 615 CAN Communication System Description......................................................................................................................................................................................... 615 Schematic and Routing Diagram.................................................................................................................................................................................................... 617 Transmission Control Module (TCM) Wiring Diagram............................................................................................................................................................................. 617 Automatic Gear Shift Table................................................................................................................................................................................................... 619 Component Location............................................................................................................................................................................................................... 620 Electronic Shift Control System Components Location.......................................................................................................................................................................... 620 Diagnostic Information and Procedures............................................................................................................................................................................................ 622 A/T System Check............................................................................................................................................................................................................. 622 Visual Inspection............................................................................................................................................................................................................ 624 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 625 DTC Table.................................................................................................................................................................................................................... 625 DTC Check.................................................................................................................................................................................................................... 626 DTC Clearance................................................................................................................................................................................................................ 627 Fail-Safe Table.............................................................................................................................................................................................................. 627 Scan Tool Data............................................................................................................................................................................................................... 630 A/T Basic Check.............................................................................................................................................................................................................. 633 Road Test.................................................................................................................................................................................................................... 634 Manual Road Test............................................................................................................................................................................................................. 636 Engine Brake Test............................................................................................................................................................................................................ 637 Stall Test................................................................................................................................................................................................................... 637 Time Lag Test................................................................................................................................................................................................................ 638 Line Pressure Test........................................................................................................................................................................................................... 638 “P” Range Test............................................................................................................................................................................................................... 639 A/T Symptom Diagnosis........................................................................................................................................................................................................ 640 No Gear Shift to 4th gear.................................................................................................................................................................................................... 647 No Lock-Up Occurs............................................................................................................................................................................................................ 648 DTC P0705: Transmission Range Sensor Circuit Malfunction..................................................................................................................................................................... 649 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................................................................................................. 651 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low................................................................................................................................................................. 653 DTC P0713: Transmission Fluid Temperature Sensor Circuit High................................................................................................................................................................ 654 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction.................................................................................................................................................................. 655 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal....................................................................................................................................................................... 657 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON............................................................................................................................................... 659 DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction................................................................................................................................................................ 660 DTC P0787: Shift / Timing Solenoid Control Circuit Low....................................................................................................................................................................... 662 DTC P0788: Shift / Timing Solenoid Control Circuit High...................................................................................................................................................................... 664 DTC P0962: Pressure Control Solenoid Control Circuit Low..................................................................................................................................................................... 666 DTC P0963: Pressure Control Solenoid Control Circuit High.................................................................................................................................................................... 668 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low................................................................................................................. 670 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High.................................................................................................................................... 672 DTC P1702: Internal Control Module Memory Check Sum Error.................................................................................................................................................................... 674 DTC P1703: Can Invalid Data - TCM............................................................................................................................................................................................ 674 DTC P1723: Range Select Switch Malfunction................................................................................................................................................................................... 674 DTC P1774: Control Module Communication Bus Off.............................................................................................................................................................................. 676 DTC P1775: High Speed CAN Communication Bus Off (Transmission Error)......................................................................................................................................................... 681 DTC P1777: TCM Lost Communication with ECM (Reception Error)................................................................................................................................................................. 684 DTC P1778: TCM Lost Communication with BCM (Reception Error)................................................................................................................................................................. 687 DTC P1878: Torque Converter Clutch Shudder................................................................................................................................................................................... 690 DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High...................................................................................................................................... 690 DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low............................................................................................................................... 693 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 695 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 699 Brake Interlock System Inspection............................................................................................................................................................................................ 700 Repair Instructions.............................................................................................................................................................................................................. 701 Learning Control Initialization.............................................................................................................................................................................................. 701 A/T Fluid Level Check........................................................................................................................................................................................................ 701 A/T Fluid Change............................................................................................................................................................................................................. 702 Selector Lever Components.................................................................................................................................................................................................... 702 Select Lever Assembly Installation........................................................................................................................................................................................... 702 Select Lever Knob Installation............................................................................................................................................................................................... 703 Selector Lever Inspection.................................................................................................................................................................................................... 703 Select Cable Components...................................................................................................................................................................................................... 703 Select Cable Removal and Installation........................................................................................................................................................................................ 704 Select Cable Adjustment...................................................................................................................................................................................................... 704 Transmission Range Sensor (Shift Switch) Inspection and Adjustment........................................................................................................................................................... 704 Output Shaft Speed Sensor (VSS) Removal and Installation..................................................................................................................................................................... 705 Output Shaft Speed Sensor (VSS) Inspection................................................................................................................................................................................... 705 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 706 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 706 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 706 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 707 “3” Position Switch Inspection............................................................................................................................................................................................... 707 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation................................................................................................................................... 708 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection................................................................................................................................................ 709 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...................................................................................................... 711 Pressure Control Solenoid Valve Inspection................................................................................................................................................................................... 711 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 712 A/T Relay Inspection......................................................................................................................................................................................................... 713 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 713 Shift Lock Solenoid Inspection............................................................................................................................................................................................... 714 Shift Lock Solenoid Replacement.............................................................................................................................................................................................. 714 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 715 A/T Fluid Cooler Hoses Replacement........................................................................................................................................................................................... 716 Automatic Transaxle Unit Components.......................................................................................................................................................................................... 716 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................... 717 Automatic Transaxle Assembly Components...................................................................................................................................................................................... 719 Automatic Transaxle Unit Disassembly......................................................................................................................................................................................... 720 Oil Pump Assembly Components................................................................................................................................................................................................. 731 Oil Pump Assembly Disassembly and Reassembly................................................................................................................................................................................. 732 Oil Pump Assembly Inspection................................................................................................................................................................................................. 733 Direct Clutch Assembly Components............................................................................................................................................................................................ 734 Direct Clutch Assembly Preliminary Check..................................................................................................................................................................................... 734 Direct Clutch Assembly Disassembly and Reassembly............................................................................................................................................................................ 735 Direct Clutch Assembly Inspection............................................................................................................................................................................................ 737 Forward and Reverse Clutch Assembly Components............................................................................................................................................................................... 738 Forward and Reverse Clutch Assembly Preliminary Check........................................................................................................................................................................ 738 Forward and Reverse Clutch Assembly Disassembly and Reassembly............................................................................................................................................................... 739 Forward and Reverse Clutch Assembly Inspection............................................................................................................................................................................... 742 2nd Brake Piston Assembly Components......................................................................................................................................................................................... 743 2nd Brake Piston Assembly Disassembly and Reassembly......................................................................................................................................................................... 743 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components.................................................................................................................................................... 744 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly.................................................................................................................................... 745 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection.................................................................................................................................................... 746 Countershaft Assembly Components............................................................................................................................................................................................. 747 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 747 Valve Body Assembly Components............................................................................................................................................................................................... 748 Valve Body Assembly Disassembly and Reassembly............................................................................................................................................................................... 749 Differential Assembly Components............................................................................................................................................................................................. 750 Differential Assembly Disassembly and Reassembly............................................................................................................................................................................. 750 Differential Assembly Inspection............................................................................................................................................................................................. 752 Torque Converter Housing Disassembly and Reassembly.......................................................................................................................................................................... 752 Transaxle Case Disassembly and Reassembly.................................................................................................................................................................................... 754 Automatic Transaxle Unit Inspection and Adjustment........................................................................................................................................................................... 756 Automatic Transaxle Unit Assembly............................................................................................................................................................................................ 758 Specifications................................................................................................................................................................................................................... 774 Tightening Torque Specifications............................................................................................................................................................................................. 774 Special Tools and Equipment...................................................................................................................................................................................................... 775 Recommended Service Material................................................................................................................................................................................................. 775 Special Tool................................................................................................................................................................................................................. 775 Manual Transmission.................................................................................................................................................................................................................. 778 For M13 Engine Model............................................................................................................................................................................................................. 778 General Description.......................................................................................................................................................................................................... 778 Manual Transaxle Construction and Servicing.............................................................................................................................................................................. 778 Diagnostic Information and Procedures........................................................................................................................................................................................ 780 Manual Transaxle Symptom Diagnosis....................................................................................................................................................................................... 780 Repair Instructions.......................................................................................................................................................................................................... 780 Manual Transaxle Oil Change.............................................................................................................................................................................................. 780 Differential Side Oil Seal Replacement................................................................................................................................................................................... 781 Gear Shift Control Lever and Cable Components............................................................................................................................................................................ 782 Gear Shift Control Lever and Cable Removal and Installation.............................................................................................................................................................. 783 Gear Select Control Cable Adjustment..................................................................................................................................................................................... 783 Vehicle Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................... 784 Back Up Lamp Switch Removal and Installation............................................................................................................................................................................. 784 Back Up Lamp Switch Inspection........................................................................................................................................................................................... 785 Manual Transaxle Unit Components......................................................................................................................................................................................... 785 Manual Transaxle Unit Dismounting and Remounting......................................................................................................................................................................... 786 Gear Shift and Select Shaft Assembly Components.......................................................................................................................................................................... 788 Gear Shift and Select Shaft Assembly Removal and Installation............................................................................................................................................................ 789 Gear Shift and Select Shaft Disassembly and Assembly..................................................................................................................................................................... 790 Manual Transaxle Assembly Components..................................................................................................................................................................................... 791 Fifth Gear Disassembly and Assembly...................................................................................................................................................................................... 792 Manual Transaxle Assembly Disassembly and Reassembly..................................................................................................................................................................... 795 Transaxle Right Case Disassembly and Assembly............................................................................................................................................................................ 799 Transaxle Left Case Disassembly and Assembly............................................................................................................................................................................. 800 Input Shaft and Countershaft Components.................................................................................................................................................................................. 801 Input Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 802 Countershaft Assembly Disassembly and Reassembly......................................................................................................................................................................... 804 Synchronizer Parts Inspection............................................................................................................................................................................................ 807 Gear Shift Shaft Components.............................................................................................................................................................................................. 807 5th and Reverse Gear Shift Shafts Disassembly and Assembly............................................................................................................................................................... 807 Gear Shift Shaft and Fork Inspection..................................................................................................................................................................................... 808 Differential Components.................................................................................................................................................................................................. 808 Differential Disassembly and Assembly.................................................................................................................................................................................... 809 Specifications............................................................................................................................................................................................................... 811 Tightening Torque Specifications......................................................................................................................................................................................... 811 Special Tools and Equipment.................................................................................................................................................................................................. 811 Recommended Service Material............................................................................................................................................................................................. 811 Special Tool............................................................................................................................................................................................................. 812 For M15 Engine Model............................................................................................................................................................................................................. 814 General Description.......................................................................................................................................................................................................... 814 Manual Transaxle Construction and Servicing.............................................................................................................................................................................. 814 Diagnostic Information and Procedures........................................................................................................................................................................................ 816 Manual Transaxle Symptom Diagnosis....................................................................................................................................................................................... 816 Repair Instructions.......................................................................................................................................................................................................... 816 Manual Transaxle Oil Change.............................................................................................................................................................................................. 816 Differential Side Oil Seal Replacement................................................................................................................................................................................... 817 Gear Shift Control Lever and Cable Components............................................................................................................................................................................ 818 Gear Shift Control Lever and Cable Removal and Installation.............................................................................................................................................................. 819 Gear Select Control Cable Adjustment..................................................................................................................................................................................... 819 Vehicle Speed Sensor (VSS) Removal and Installation...................................................................................................................................................................... 820 Back Up Lamp Switch Removal and Installation............................................................................................................................................................................. 820 Back Up Lamp Switch Inspection........................................................................................................................................................................................... 821 Manual Transaxle Unit Components......................................................................................................................................................................................... 821 Manual Transaxle Unit Dismounting and Remounting......................................................................................................................................................................... 822 Gear Shift and Select Shaft Assembly Components.......................................................................................................................................................................... 824 Gear Shift and Select Shaft Assembly Removal and Installation............................................................................................................................................................ 824 Gear Shift and Select Shaft Disassembly and Assembly..................................................................................................................................................................... 825 Manual Transaxle Assembly Components..................................................................................................................................................................................... 826 Fifth Gear Disassembly and Assembly...................................................................................................................................................................................... 827 Manual Transaxle Assembly Disassembly and Reassembly..................................................................................................................................................................... 829 Transaxle Right Case Disassembly and Assembly............................................................................................................................................................................ 835 Transaxle Left Case Disassembly and Assembly............................................................................................................................................................................. 836 Input Shaft and Countershaft Components.................................................................................................................................................................................. 837 Input Shaft Assembly Disassembly and Reassembly.......................................................................................................................................................................... 838 Countershaft Assembly Disassembly and Reassembly......................................................................................................................................................................... 840 Synchronizer Parts Inspection............................................................................................................................................................................................ 843 Gear Shift Shaft Components.............................................................................................................................................................................................. 843 5th and Reverse Gear Shift Shafts Disassembly and Assembly............................................................................................................................................................... 844 Gear Shift Shaft and Fork Inspection..................................................................................................................................................................................... 844 Differential Components.................................................................................................................................................................................................. 845 Differential Disassembly and Assembly.................................................................................................................................................................................... 845 Specifications............................................................................................................................................................................................................... 847 Tightening Torque Specifications......................................................................................................................................................................................... 847 Special Tools and Equipment.................................................................................................................................................................................................. 848 Recommended Service Material............................................................................................................................................................................................. 848 Special Tool............................................................................................................................................................................................................. 848 Clutch............................................................................................................................................................................................................................... 851 General Description.............................................................................................................................................................................................................. 851 Clutch Construction.......................................................................................................................................................................................................... 851 Diagnostic Information and Procedures............................................................................................................................................................................................ 852 Clutch System Symptom Diagnosis.............................................................................................................................................................................................. 852 Repair Instructions.............................................................................................................................................................................................................. 852 Clutch Pedal Inspection...................................................................................................................................................................................................... 852 Clutch Fluid Level Inspection................................................................................................................................................................................................ 853 Air Bleeding of Clutch System................................................................................................................................................................................................ 853 Clutch Fluid Pipe and Hose Components........................................................................................................................................................................................ 854 Clutch Fluid Pipe Removal and Installation................................................................................................................................................................................... 855 Clutch Fluid Pipe Inspection................................................................................................................................................................................................. 855 Clutch Master Cylinder Removal and Installation.............................................................................................................................................................................. 855 Clutch Operating Cylinder Removal and Installation........................................................................................................................................................................... 856 Clutch Pedal and Clutch Pedal Bracket Components............................................................................................................................................................................. 857 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................................................................................................ 857 Clutch Cover, Clutch Disc and Flywheel Removal and Installation.............................................................................................................................................................. 858 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................................................................................................ 859 Clutch Release System Removal and Installation............................................................................................................................................................................... 860 Clutch Release System Inspection............................................................................................................................................................................................. 861 Specifications................................................................................................................................................................................................................... 862 Tightening Torque Specifications............................................................................................................................................................................................. 862 Special Tools and Equipment...................................................................................................................................................................................................... 862 Recommended Service Material................................................................................................................................................................................................. 862 Special Tool................................................................................................................................................................................................................. 863 Automated Manual Transaxle........................................................................................................................................................................................................... 864 Precautions...................................................................................................................................................................................................................... 864 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 864 General Description.............................................................................................................................................................................................................. 864 Automated Manual Transaxle Description....................................................................................................................................................................................... 864 Automated Manual Transaxle Diagnosis General Description..................................................................................................................................................................... 867 On-Board Diagnostic System Description....................................................................................................................................................................................... 867 CAN Communication System Description......................................................................................................................................................................................... 868 Schematic and Routing Diagram.................................................................................................................................................................................................... 868 TCM (Automated Manual Transaxle) Wiring Diagram.............................................................................................................................................................................. 868 Automatic Gear Shift Table................................................................................................................................................................................................... 870 Component Location............................................................................................................................................................................................................... 872 Electronic Shift Control System Components Location.......................................................................................................................................................................... 872 Diagnostic Information and Procedures............................................................................................................................................................................................ 873 Automated Manual Transaxle System Check...................................................................................................................................................................................... 873 Visual Inspection............................................................................................................................................................................................................ 876 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 877 Automated Manual Transaxle Warning Lamp Check................................................................................................................................................................................ 877 DTC Table.................................................................................................................................................................................................................... 877 DTC Check.................................................................................................................................................................................................................... 879 DTC Clearance................................................................................................................................................................................................................ 880 Fail-Safe Table.............................................................................................................................................................................................................. 881 Scan Tool Data............................................................................................................................................................................................................... 882 Automated Manual Transaxle Symptom Diagnosis................................................................................................................................................................................. 885 Automated Manual Transaxle Warning Lamp Does Not Come ON at Ignition Switch ON............................................................................................................................................... 889 Automated Manual Transaxle Warning Lamp Remains ON at Ignition Switch ON..................................................................................................................................................... 891 Starting Motor Control Relay Circuit Check................................................................................................................................................................................... 892 DTC P0705: Transmission Range Sensor Circuit Malfunction..................................................................................................................................................................... 894 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction.................................................................................................................................................................. 896 DTC P0722: Output Speed Sensor Circuit....................................................................................................................................................................................... 898 DTC P0727: Engine Speed Input Circuit........................................................................................................................................................................................ 899 DTC P0807: Clutch Position Sensor Circuit Low................................................................................................................................................................................ 900 DTC P0808: Clutch Position Sensor Circuit High............................................................................................................................................................................... 902 DTC P0810: Clutch Position Control Error..................................................................................................................................................................................... 904 DTC P0902 / P0903: Clutch Actuator Circuit Low / High........................................................................................................................................................................ 906 DTC P0906: Gate Select Position Circuit Low.................................................................................................................................................................................. 908 DTC P0907: Gate Select Position Circuit High................................................................................................................................................................................. 910 DTC P0909: Gate Select Control Error......................................................................................................................................................................................... 912 DTC P0912 / P0913: Gate Select Actuator Circuit Low / High................................................................................................................................................................... 914 DTC P0916: Gear Shift Position Circuit Low................................................................................................................................................................................... 916 DTC P0917: Gear Shift Position Circuit High.................................................................................................................................................................................. 918 DTC P0919: Gear Shift Position Control Error................................................................................................................................................................................. 920 DTC P1703: CAN Invalid Data - Automated Manual Transaxle Control............................................................................................................................................................. 922 DTC P1774: Control Module Communication Bus Off.............................................................................................................................................................................. 923 DTC P1777: TCM (Automated Manual Transaxle) Lost Communication with ECM (Reception Error).................................................................................................................................... 926 DTC P1778: TCM (Automated Manual Transaxle) Lost Communication with BCM (Reception Error).................................................................................................................................... 928 DTC P1840: TCM (Automated Manual Transaxle) System Voltage................................................................................................................................................................... 930 DTC P1841 / P1842: CPU Malfunction / TCM (Automated Manual Transaxle) Internal Module Keep Alive Memory Error................................................................................................................ 931 DTC P1843: Brake Switch “A/B” Error.......................................................................................................................................................................................... 931 DTC P1845: Warning Buzzer Circuit Malfunction................................................................................................................................................................................ 933 DTC P1846: Reverse Input Circuit No Signal................................................................................................................................................................................... 933 DTC P1847: Reverse Input Circuit Short....................................................................................................................................................................................... 935 DTC P1848: Motor Relay Circuit Low........................................................................................................................................................................................... 936 DTC P1849: Motor Relay Circuit High.......................................................................................................................................................................................... 938 DTC P1856: Clutch Position Sensor Circuit “B” Low............................................................................................................................................................................ 939 DTC P1857: Clutch Position Sensor Circuit “B” High........................................................................................................................................................................... 941 DTC P1858: Gate Select Position Circuit “B” Low.............................................................................................................................................................................. 943 DTC P1859: Gate Select Position Circuit “B” High............................................................................................................................................................................. 944 DTC P1880 / P1881: Gear Shift Actuator Circuit Low / High.................................................................................................................................................................... 946 DTC P1882: Gear Shift Position Circuit “B” Low............................................................................................................................................................................... 948 DTC P1883: Gear Shift Position Circuit “B” High.............................................................................................................................................................................. 950 DTC P1900: Clutch Position Sensor “A/B” Correlation.......................................................................................................................................................................... 951 DTC P1901: Gear Shift Position Sensor “A/B” Correlation...................................................................................................................................................................... 953 DTC P1960: Gate Select Position Sensor “A/B” Correlation..................................................................................................................................................................... 955 TCM (Automated Manual Transaxle) Power and Ground Circuit Check.............................................................................................................................................................. 956 Inspection of TCM (Automated Manual Transaxle) and Its Circuits.............................................................................................................................................................. 957 Repair Instructions.............................................................................................................................................................................................................. 965 TCM (Automated Manual Transaxle) Initialization.............................................................................................................................................................................. 965 Clutch Position Control...................................................................................................................................................................................................... 965 Automated Manual Transaxle Oil Change........................................................................................................................................................................................ 965 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 966 Shift Selector Components.................................................................................................................................................................................................... 967 Shift Selector Assembly Removal and Installation............................................................................................................................................................................. 967 Shift Selector Assembly Disassembly and Reassembly........................................................................................................................................................................... 968 Shift Selector Inspection.................................................................................................................................................................................................... 970 Clutch Stroke Sensor Removal and Installation................................................................................................................................................................................ 971 Clutch Stroke Sensor Inspection.............................................................................................................................................................................................. 972 Clutch Actuator Removal and Installation..................................................................................................................................................................................... 972 Clutch Actuator Inspection................................................................................................................................................................................................... 973 Shift and Select Stroke Sensor Removal and Installation...................................................................................................................................................................... 974 Shift Stroke Sensor and Select Stroke Sensor Inspection...................................................................................................................................................................... 974 Shift and Select Actuator Removal and Installation........................................................................................................................................................................... 975 Shift and Select Actuator Inspection......................................................................................................................................................................................... 976 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 977 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 977 Neutral Start Switch Removal and Installation................................................................................................................................................................................ 977 Neutral Start Switch Inspection.............................................................................................................................................................................................. 978 Back Up Lamp Switch Removal and Installation................................................................................................................................................................................. 978 Back Up Lamp Switch Inspection............................................................................................................................................................................................... 978 Output Shaft Speed Sensor (VSS) Removal and Installation..................................................................................................................................................................... 978 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 979 Motor Relay Inspection....................................................................................................................................................................................................... 979 Automated Manual Transaxle Unit Components................................................................................................................................................................................... 980 Automated Manual Transaxle Unit Dismounting and Remounting................................................................................................................................................................... 980 Automated Manual Transaxle Assembly Components............................................................................................................................................................................... 982 Automated Manual Transaxle Assembly Disassembly and Reassembly............................................................................................................................................................... 983 Left Case Assembly Disassembly and Reassembly................................................................................................................................................................................ 985 Countershaft Tapered Roller Bearing Preload Adjustment....................................................................................................................................................................... 986 Input Shaft Bearing Shim Adjustment.......................................................................................................................................................................................... 988 Differential Left Side Bearing Preload Adjustment............................................................................................................................................................................ 988 Right Case Assembly Disassembly and Reassembly............................................................................................................................................................................... 989 Input Shaft Assembly Components.............................................................................................................................................................................................. 991 Input Shaft Assembly Disassembly and Reassembly.............................................................................................................................................................................. 991 Input Shaft Assembly Inspection.............................................................................................................................................................................................. 994 Countershaft Components...................................................................................................................................................................................................... 996 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 997 Countershaft Assembly Inspection............................................................................................................................................................................................. 999 Gear Shift Shaft Components..................................................................................................................................................................................................1001 Gear Shift Shaft Disassembly and Reassembly..................................................................................................................................................................................1001 Gear Shift Shaft Inspection..................................................................................................................................................................................................1003 Differential Components......................................................................................................................................................................................................1003 Differential Assembly Disassembly and Reassembly.............................................................................................................................................................................1003 Clutch Cover and Clutch Disc Components......................................................................................................................................................................................1006 Clutch Cover and Clutch Disc Removal and Installation........................................................................................................................................................................1006 Clutch Release System Component Removal and Installation.....................................................................................................................................................................1007 Clutch Inspection............................................................................................................................................................................................................1008 Specifications...................................................................................................................................................................................................................1009 Tightening Torque Specifications.............................................................................................................................................................................................1009 Special Tools and Equipment......................................................................................................................................................................................................1010 Recommended Service Material.................................................................................................................................................................................................1010 Special Tool.................................................................................................................................................................................................................1010 Steering.................................................................................................................................................................................................................................1013 Precautions..........................................................................................................................................................................................................................1015 Precautions......................................................................................................................................................................................................................1015 Precautions on Steering......................................................................................................................................................................................................1015 Steering General Diagnosis...........................................................................................................................................................................................................1016 Precautions......................................................................................................................................................................................................................1016 Precautions for Steering Diagnosis...........................................................................................................................................................................................1016 Diagnostic Information and Procedures............................................................................................................................................................................................1016 Steering Symptom Diagnosis...................................................................................................................................................................................................1016 Steering Wheel and Column............................................................................................................................................................................................................1018 Precautions......................................................................................................................................................................................................................1018 Service Precautions of Steering Wheel and Column.............................................................................................................................................................................1018 Diagnostic Information and Procedures............................................................................................................................................................................................1018 Checking Steering Column for Accident Damage.................................................................................................................................................................................1018 Repair Instructions..............................................................................................................................................................................................................1019 Steering Wheel and Column Construction.......................................................................................................................................................................................1019 Steering Wheel Removal and Installation......................................................................................................................................................................................1020 Contact Coil Cable Assembly Removal and Installation.........................................................................................................................................................................1021 Centering Contact Coil Cable Assembly........................................................................................................................................................................................1021 Contact Coil Cable Assembly Inspection.......................................................................................................................................................................................1022 Steering Column Removal and Installation.....................................................................................................................................................................................1022 Steering Column Inspection...................................................................................................................................................................................................1024 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................1024 Steering Lower Shaft Removal and Installation................................................................................................................................................................................1025 Specifications...................................................................................................................................................................................................................1027 Tightening Torque Specifications.............................................................................................................................................................................................1027 Special Tools and Equipment......................................................................................................................................................................................................1027 Special Tool.................................................................................................................................................................................................................1027 Power Assisted Steering System.......................................................................................................................................................................................................1028 Precautions......................................................................................................................................................................................................................1028 Steering System Note.........................................................................................................................................................................................................1028 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1028 General Description..............................................................................................................................................................................................................1028 P/S System Description.......................................................................................................................................................................................................1028 EPS Diagnosis General Description............................................................................................................................................................................................1029 On-Board Diagnostic System Description.......................................................................................................................................................................................1029 Schematic and Routing Diagram....................................................................................................................................................................................................1030 EPS System Wiring Circuit Diagram............................................................................................................................................................................................1030 Diagnostic Information and Procedures............................................................................................................................................................................................1031 EPS System Check.............................................................................................................................................................................................................1031 “EPS” Warning Lamp Check.....................................................................................................................................................................................................1032 DTC Check....................................................................................................................................................................................................................1033 DTC Clearance................................................................................................................................................................................................................1033 DTC Table....................................................................................................................................................................................................................1033 Scan Tool Data...............................................................................................................................................................................................................1035 P/S System Symptom Diagnosis.................................................................................................................................................................................................1035 Serial Data Link Circuit Check...............................................................................................................................................................................................1036 “EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stops...................................................................................................................................................1038 “EPS” Warning Lamp Comes ON Steady and Engine Start..........................................................................................................................................................................1040 DTC C1113 / C1117 / C1118: Torque Sensor Circuit Failure.....................................................................................................................................................................1041 DTC C1114: Torque Sensor 5 V Power Supply Circuit Failure....................................................................................................................................................................1042 DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure...................................................................................................................................................................1044 DTC C1121 / C1123 / C1124: VSS Circuit Failure...............................................................................................................................................................................1046 DTC C1122: Engine Speed Signal Circuit Failure...............................................................................................................................................................................1048 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure.....................................................................................................................................................................1049 DTC C1153: P/S Control Module Power Supply Circuit Voltage Low...............................................................................................................................................................1050 DTC C1155: P/S Control Module Failure........................................................................................................................................................................................1052 Inspection of P/S Control Module and Its Circuits............................................................................................................................................................................1052 Steering Wheel Play Check....................................................................................................................................................................................................1054 Steering Force Check.........................................................................................................................................................................................................1055 Repair Instructions..............................................................................................................................................................................................................1056 Steering Gear Case Assembly Components.......................................................................................................................................................................................1056 Tie-Rod End Boot On-Vehicle Inspection.......................................................................................................................................................................................1057 Tie-Rod End Removal and Installation.........................................................................................................................................................................................1057 Tie-Rod End Inspection.......................................................................................................................................................................................................1058 Steering Shaft Joint On-Vehicle Inspection...................................................................................................................................................................................1058 Steering Gear Case Assembly Removal and Installation.........................................................................................................................................................................1058 Steering Rack Boot Inspection................................................................................................................................................................................................1060 Tie-Rod / Rack Boot Removal and Installation.................................................................................................................................................................................1060 Steering Rack Plunger Removal and Installation...............................................................................................................................................................................1061 Steering Rack Plunger Inspection.............................................................................................................................................................................................1062 P/S Control Module Removal and Installation..................................................................................................................................................................................1062 Torque Sensor Inspection.....................................................................................................................................................................................................1063 Motor Assembly Inspection....................................................................................................................................................................................................1063 Specifications...................................................................................................................................................................................................................1064 Tightening Torque Specifications.............................................................................................................................................................................................1064 Special Tools and Equipment......................................................................................................................................................................................................1064 Recommended Service Material.................................................................................................................................................................................................1064 Special Tool.................................................................................................................................................................................................................1064 HVAC.....................................................................................................................................................................................................................................1067 Precautions..........................................................................................................................................................................................................................1068 Precautions......................................................................................................................................................................................................................1068 Precautions on HVAC..........................................................................................................................................................................................................1068 Heater and Ventilation...............................................................................................................................................................................................................1069 General Description..............................................................................................................................................................................................................1069 Heater and Ventilation Construction..........................................................................................................................................................................................1069 Schematic and Routing Diagram....................................................................................................................................................................................................1070 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................1070 Diagnostic Information and Procedures............................................................................................................................................................................................1071 Heater and Ventilation Symptom Diagnosis.....................................................................................................................................................................................1071 Repair Instructions..............................................................................................................................................................................................................1072 HVAC Unit Components.........................................................................................................................................................................................................1072 HVAC Unit Removal and Installation...........................................................................................................................................................................................1073 Blower Motor Removal and Installation........................................................................................................................................................................................1073 Blower Motor Inspection......................................................................................................................................................................................................1073 Blower Motor Resistor Removal and Installation...............................................................................................................................................................................1074 Blower Motor Resistor Inspection.............................................................................................................................................................................................1074 Blower Motor Relay Inspection................................................................................................................................................................................................1075 HVAC Control Unit Components.................................................................................................................................................................................................1076 HVAC Control Unit Removal and Installation...................................................................................................................................................................................1076 Blower Speed Selector Inspection.............................................................................................................................................................................................1078 Air Intake Selector Inspection...............................................................................................................................................................................................1078 Air Intake Control Actuator Removal and Installation.........................................................................................................................................................................1079 Air Intake Control Actuator Inspection.......................................................................................................................................................................................1079 Center Ventilation Louver Removal and Installation...........................................................................................................................................................................1079 Side Ventilation Louver Removal and Installation.............................................................................................................................................................................1080 Air Filter (If Equipped) Removal and Installation............................................................................................................................................................................1081 Air Filter Cleaning (If Equipped)............................................................................................................................................................................................1081 Air Conditioning System..............................................................................................................................................................................................................1082 Precautions......................................................................................................................................................................................................................1082 A/C System Caution...........................................................................................................................................................................................................1082 Precautions on Servicing A/C System..........................................................................................................................................................................................1082 General Description..............................................................................................................................................................................................................1083 Refrigerant Type Identification..............................................................................................................................................................................................1083 Sub-Cool A/C System Description..............................................................................................................................................................................................1084 A/C Operation Description....................................................................................................................................................................................................1085 Schematic and Routing Diagram....................................................................................................................................................................................................1085 Major Components of A/C System...............................................................................................................................................................................................1085 A/C System Wiring Diagram....................................................................................................................................................................................................1087 Diagnostic Information and Procedures............................................................................................................................................................................................1088 A/C System Symptom Diagnosis.................................................................................................................................................................................................1088 Abnormal Noise Symptom Diagnosis of A/C System...............................................................................................................................................................................1090 A/C System Performance Inspection............................................................................................................................................................................................1091 A/C System Inspection at ECM.................................................................................................................................................................................................1096 Repair Instructions..............................................................................................................................................................................................................1098 Operation Procedure for Refrigerant Charge...................................................................................................................................................................................1098 Condenser Assembly On-Vehicle Inspection.....................................................................................................................................................................................1103 Condenser Assembly Removal and Installation..................................................................................................................................................................................1103 Desiccant Removal and Installation...........................................................................................................................................................................................1104 HVAC Unit Components.........................................................................................................................................................................................................1105 HVAC Unit Removal and Installation...........................................................................................................................................................................................1106 Evaporator Inspection........................................................................................................................................................................................................1106 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation...............................................................................................................................................1106 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection.............................................................................................................................................................1107 Expansion Valve Removal and Installation.....................................................................................................................................................................................1107 Expansion Valve Inspection...................................................................................................................................................................................................1108 A/C Refrigerant Pressure Sensor and Its Circuit Inspection...................................................................................................................................................................1108 A/C Refrigerant Pressure Sensor Removal and Installation.....................................................................................................................................................................1108 A/C Switch Inspection........................................................................................................................................................................................................1108 Compressor Relay Inspection..................................................................................................................................................................................................1109 Compressor Drive Belt Inspection and Adjustment..............................................................................................................................................................................1109 Compressor Drive Belt Removal and Installation...............................................................................................................................................................................1110 Compressor Assembly Removal and Installation.................................................................................................................................................................................1110 Compressor Assembly Components...............................................................................................................................................................................................1111 Magnet Clutch Inspection.....................................................................................................................................................................................................1111 Magnet Clutch Removal and Installation.......................................................................................................................................................................................1111 Thermal Switch Inspection....................................................................................................................................................................................................1113 Thermal Switch Removal and Installation......................................................................................................................................................................................1113 Relief Valve Inspection......................................................................................................................................................................................................1113 Relief valve Removal and Installation........................................................................................................................................................................................1113 Specifications...................................................................................................................................................................................................................1114 Tightening Torque Specifications.............................................................................................................................................................................................1114 Special Tools and Equipment......................................................................................................................................................................................................1114 Recommended Service Material.................................................................................................................................................................................................1114 Special Tool.................................................................................................................................................................................................................1114 Restraint................................................................................................................................................................................................................................1115 Precautions..........................................................................................................................................................................................................................1117 Precautions......................................................................................................................................................................................................................1117 Precautions on Restraint.....................................................................................................................................................................................................1117 Seat Belts...........................................................................................................................................................................................................................1118 Precautions......................................................................................................................................................................................................................1118 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................1118 General Description..............................................................................................................................................................................................................1118 Seat Belt Construction.......................................................................................................................................................................................................1118 Diagnostic Information and Procedures............................................................................................................................................................................................1119 Repair and Inspection Required after Accident................................................................................................................................................................................1119 Repair Instructions..............................................................................................................................................................................................................1120 Front Seat Belt Components...................................................................................................................................................................................................1120 Front Seat Belt Removal and Installation.....................................................................................................................................................................................1121 Front Seat Belt Inspection...................................................................................................................................................................................................1122 Rear Seat Belt Components....................................................................................................................................................................................................1123 Rear Seat Belt Removal and Installation......................................................................................................................................................................................1124 Rear Seat Belt Inspection....................................................................................................................................................................................................1124 Specifications...................................................................................................................................................................................................................1124 Tightening Torque Specifications.............................................................................................................................................................................................1124 Air Bag System.......................................................................................................................................................................................................................1125 Precautions......................................................................................................................................................................................................................1125 Precautions on Service and Diagnosis of Air Bag System.......................................................................................................................................................................1125 Precautions on Handling and Storage of Air Bag System Components.............................................................................................................................................................1125 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................1129 General Description..............................................................................................................................................................................................................1129 Air Bag System Construction..................................................................................................................................................................................................1129 Air Bag System Input / Output Table..........................................................................................................................................................................................1130 Schematic and Routing Diagram....................................................................................................................................................................................................1131 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................1131 Component Location...............................................................................................................................................................................................................1133 Air Bag System Components, Wiring and Connectors Location....................................................................................................................................................................1133 Diagnostic Information and Procedures............................................................................................................................................................................................1134 Air Bag Diagnostic System Check..............................................................................................................................................................................................1134 Air Bag Diagnostic System Check Flow.........................................................................................................................................................................................1134 DTC Table....................................................................................................................................................................................................................1135 DTC Check....................................................................................................................................................................................................................1136 DTC Clearance................................................................................................................................................................................................................1136 Scan Tool Data...............................................................................................................................................................................................................1136 “AIR BAG” Warning Lamp Comes ON Steady.......................................................................................................................................................................................1137 “AIR BAG” Warning Lamp Does Not Come ON......................................................................................................................................................................................1139 “AIR BAG” Warning Lamp Flashes...............................................................................................................................................................................................1140 DTC B1013: SDM fault.........................................................................................................................................................................................................1141 DTC B1014: “AIR BAG” Warning Lamp Circuit Failure............................................................................................................................................................................1141 DTC B1016: Power Source Voltage High.........................................................................................................................................................................................1143 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1144 DTC B1021: Front Air Bag Module Deployed.....................................................................................................................................................................................1146 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed................................................................................................................................................................1147 DTC B1026: Pretensioner Activated............................................................................................................................................................................................1147 DTC B1027: Reusable Number Exceeded..........................................................................................................................................................................................1148 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1148 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1153 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1157 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1161 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1165 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1168 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1171 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1174 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1177 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1179 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1181 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1183 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.........................................................................................................................................1185 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low..........................................................................................................................................1188 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.........................................................................................................................................1191 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit..................................................................................................................................1194 DTC B1071: Forward-Sensor Performance Problem................................................................................................................................................................................1197 DTC B1072: Forward-Sensor Communication Error................................................................................................................................................................................1197 DTC B1073: Forward-Sensor Circuit Short to Ground............................................................................................................................................................................1197 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open.............................................................................................................................................................1199 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem........................................................................................................................................................1201 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error........................................................................................................................................................1201 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground....................................................................................................................................................1201 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open.....................................................................................................................................1202 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID............................................................................................................................................................1204 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High.................................................................................................................................1205 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low..................................................................................................................................1207 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground.................................................................................................................................1209 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit..........................................................................................................................1211 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1213 Repair and Inspection Required after Accident................................................................................................................................................................................1214 Repair Instructions..............................................................................................................................................................................................................1217 Disabling Air Bag System.....................................................................................................................................................................................................1217 Enabling Air Bag System......................................................................................................................................................................................................1217 SDM Removal and Installation.................................................................................................................................................................................................1218 SDM Inspection...............................................................................................................................................................................................................1219 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1219 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1220 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1221 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1222 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1223 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1224 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1225 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1226 Forward-Sensor Removal and Installation......................................................................................................................................................................................1226 Forward-Sensor Inspection....................................................................................................................................................................................................1227 Side-Sensor Removal and Installation.........................................................................................................................................................................................1227 Side-Sensor Inspection.......................................................................................................................................................................................................1228 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................................................................................................1229 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1230 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1240 Specifications...................................................................................................................................................................................................................1241 Tightening Torque Specifications.............................................................................................................................................................................................1241 Special Tools and Equipment......................................................................................................................................................................................................1241 Use of Special Tools.........................................................................................................................................................................................................1241 Recommended Service Material.................................................................................................................................................................................................1242 Special Tool.................................................................................................................................................................................................................1242 Body, Cab and Accessories................................................................................................................................................................................................................1245 Precautions..........................................................................................................................................................................................................................1250 Precautions......................................................................................................................................................................................................................1250 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1250 Precautions for Body Service.................................................................................................................................................................................................1250 Fastener Caution for Body Service............................................................................................................................................................................................1250 Wiring Systems.......................................................................................................................................................................................................................1251 Precautions......................................................................................................................................................................................................................1251 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1251 Precautions for Wiring System................................................................................................................................................................................................1251 General Description..............................................................................................................................................................................................................1251 Applicable model.............................................................................................................................................................................................................1251 Abbreviations................................................................................................................................................................................................................1252 Wire / Connector Color Symbols...............................................................................................................................................................................................1252 Symbols and Marks............................................................................................................................................................................................................1253 How to Read Connector Layout Diagram.........................................................................................................................................................................................1254 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1255 How to Read Ground Point.....................................................................................................................................................................................................1258 How to Read Power Supply Diagram.............................................................................................................................................................................................1258 How to Read System Circuit Diagram...........................................................................................................................................................................................1259 Harness Routing and Connector Layout Diagram.....................................................................................................................................................................................1261 Connector Layout Diagram.....................................................................................................................................................................................................1261 Engine Compartment...........................................................................................................................................................................................................1261 Instrument Panel.............................................................................................................................................................................................................1265 Door, Roof...................................................................................................................................................................................................................1269 Floor........................................................................................................................................................................................................................1271 Rear.........................................................................................................................................................................................................................1279 Ground Point.....................................................................................................................................................................................................................1280 Ground (earth) Point.........................................................................................................................................................................................................1280 Power Supply Diagram.............................................................................................................................................................................................................1281 Power Supply Diagram.........................................................................................................................................................................................................1281 Fuses and the Protected Parts................................................................................................................................................................................................1282 Fuses in Main Fuse Box.......................................................................................................................................................................................................1282 Individual Circuit Fuse Box No. 1............................................................................................................................................................................................1282 Individual Circuit Fuse Box No. 2 (In J/B)...................................................................................................................................................................................1283 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1286 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1288 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1289 System Circuit Diagram...........................................................................................................................................................................................................1294 System Circuit Diagram.......................................................................................................................................................................................................1294 A-1 Cranking System Circuit Diagram..........................................................................................................................................................................................1295 A-2 Charging System Circuit Diagram..........................................................................................................................................................................................1296 A-3 Ignition System Circuit Diagram..........................................................................................................................................................................................1297 A-4 Cooling System Circuit Diagram...........................................................................................................................................................................................1298 A-5 Engine and A/C Control System Circuit Diagram............................................................................................................................................................................1299 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1304 A-7 Immobilizer System Circuit Diagram.......................................................................................................................................................................................1306 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1307 A-9 Automated Manual Transaxle Control System Circuit Diagram................................................................................................................................................................1311 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1314 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1315 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1316 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1317 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1318 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1320 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1321 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1322 B-9 Smart Key System Circuit Diagram.........................................................................................................................................................................................1323 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................................................................................................1324 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................................................................................................1325 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................................................................................................1326 D-1 Headlight System Circuit Diagram.........................................................................................................................................................................................1328 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1330 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1331 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1332 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1333 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1334 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1336 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1337 D-9 Headlight Beam Leveling System Circuit Diagram...........................................................................................................................................................................1338 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1339 E-1 Heater System Circuit Diagram............................................................................................................................................................................................1340 F-1 Air-Bag System Circuit Diagram...........................................................................................................................................................................................1342 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1344 F-3 Power Steering System Circuit Diagram....................................................................................................................................................................................1346 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1348 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1349 G-4 Navigation System Circuit Diagram........................................................................................................................................................................................1350 List of Connectors...............................................................................................................................................................................................................1351 List of Connectors...........................................................................................................................................................................................................1351 C Connector..................................................................................................................................................................................................................1351 E Connector..................................................................................................................................................................................................................1352 G Connector..................................................................................................................................................................................................................1354 J Connector..................................................................................................................................................................................................................1355 K Connector..................................................................................................................................................................................................................1356 L Connector..................................................................................................................................................................................................................1356 O Connector..................................................................................................................................................................................................................1358 R Connector..................................................................................................................................................................................................................1358 Lighting Systems.....................................................................................................................................................................................................................1359 Component Location...............................................................................................................................................................................................................1359 Lighting System Components Location..........................................................................................................................................................................................1359 Interior Light System Location...............................................................................................................................................................................................1360 Diagnostic Information and Procedures............................................................................................................................................................................................1360 Headlight Symptom Diagnosis..................................................................................................................................................................................................1360 DRL System Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1360 Headlight Leveling Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1361 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1361 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1362 Back-Up Light Symptom Diagnosis..............................................................................................................................................................................................1362 Stop (Brake) Lamp Symptom Diagnosis..........................................................................................................................................................................................1362 Front Fog Light (If Equipped) Symptom Diagnosis..............................................................................................................................................................................1362 Rear Fog Light (If Equipped) Symptom Diagnosis...............................................................................................................................................................................1363 Illumination Cancel System (If Equipped) Symptom Diagnosis...................................................................................................................................................................1363 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1363 DRL Operation Inspection (If Equipped).......................................................................................................................................................................................1363 Inspection of DRL Controller and Its Circuits (If Equipped)..................................................................................................................................................................1363 Repair Instructions..............................................................................................................................................................................................................1365 Headlight Housing Removal and Installation...................................................................................................................................................................................1365 Headlight Bulb Replacement...................................................................................................................................................................................................1365 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1365 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1367 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1367 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1367 Hazard Warning Switch Inspection.............................................................................................................................................................................................1368 Stop (Brake) Lamp Switch Inspection..........................................................................................................................................................................................1368 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1368 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1368 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1368 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1369 License Lamp Assembly Removal and Installation...............................................................................................................................................................................1369 Front Fog Light Assembly Removal and Installation (If Equipped)..............................................................................................................................................................1370 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1370 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1370 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1370 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1371 Headlight Levering Switch (If Equipped) Inspection...........................................................................................................................................................................1371 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................................................................................................1372 Rear Fog Light Switch Inspection.............................................................................................................................................................................................1372 Illumination Cancel Switch (If Equipped) Inspection..........................................................................................................................................................................1372 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1373 General Description..............................................................................................................................................................................................................1373 CAN Communication Data of Combination Meter..................................................................................................................................................................................1373 Schematic and Routing Diagram....................................................................................................................................................................................................1374 Combination Meter Circuit Diagram............................................................................................................................................................................................1374 Component Location...............................................................................................................................................................................................................1375 Audio System Component Location..............................................................................................................................................................................................1375 Diagnostic Information and Procedures............................................................................................................................................................................................1376 Speedometer and VSS Symptom Diagnosis........................................................................................................................................................................................1376 Tacho meter Symptom Diagnosis................................................................................................................................................................................................1376 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1376 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1376 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1377 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1377 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1377 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1378 A/T Shift Position Indicator (A/T Model Only) Symptom Diagnosis..............................................................................................................................................................1378 Automated Manual Transaxle Shift Position Indicator (Automated Manual Transaxle Model Only) Symptom Diagnosis................................................................................................................1379 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1379 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1379 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1380 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1380 Horn Symptom Diagnosis.......................................................................................................................................................................................................1380 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1381 Clock Symptom Diagnosis (If Equipped)........................................................................................................................................................................................1381 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1382 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1383 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1383 Repair Instructions..............................................................................................................................................................................................................1383 Ignition Switch Removal and Installation.....................................................................................................................................................................................1383 Ignition Switch Inspection...................................................................................................................................................................................................1384 Combination Meter Removal and Installation...................................................................................................................................................................................1384 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1385 Fuel Level Sensor Inspection.................................................................................................................................................................................................1385 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1385 Oil Pressure Switch Inspection...............................................................................................................................................................................................1385 VSS Removal and Installation.................................................................................................................................................................................................1385 VSS Inspection...............................................................................................................................................................................................................1385 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1385 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1386 Parking Brake Switch Inspection..............................................................................................................................................................................................1386 Door Switch (Front / Rear Door) Inspection...................................................................................................................................................................................1386 Rear End Door Switch Inspection..............................................................................................................................................................................................1386 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1386 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1387 Instrument Panel Removal and Installation....................................................................................................................................................................................1387 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1388 Audio Unit Removal and Installation..........................................................................................................................................................................................1388 Front Speaker Removal and Installation.......................................................................................................................................................................................1389 Rear Speaker Removal and Installation (5 Door Model).........................................................................................................................................................................1389 Rear Speaker Removal and Installation (3 Door Model).........................................................................................................................................................................1389 GPS Antenna Removal and Installation (If Equipped)...........................................................................................................................................................................1390 Horn Removal and Installation................................................................................................................................................................................................1390 Horn Inspection..............................................................................................................................................................................................................1390 Horn Relay Inspection........................................................................................................................................................................................................1390 Antenna Base Removal and Installation........................................................................................................................................................................................1391 Remote Audio Control Switch Inspection.......................................................................................................................................................................................1391 Specifications...................................................................................................................................................................................................................1391 Tightening Torque Specifications.............................................................................................................................................................................................1391 Wipers / Washers.....................................................................................................................................................................................................................1392 Diagnostic Information and Procedures............................................................................................................................................................................................1392 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1392 Rear Wiper and Washer Symptom Diagnosis (If Equipped)........................................................................................................................................................................1392 Repair Instructions..............................................................................................................................................................................................................1393 Wipers and Washers Components................................................................................................................................................................................................1393 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1394 Washer Pump Inspection.......................................................................................................................................................................................................1394 Windshield Wiper Removal and Installation....................................................................................................................................................................................1394 Windshield Wiper Motor Inspection............................................................................................................................................................................................1395 Rear Wiper Removal and Installation (If Equipped)............................................................................................................................................................................1396 Rear Wiper Motor Inspection (If Equipped)....................................................................................................................................................................................1397 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1398 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1398 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1399 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1400 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1400 Rear Wiper Relay Inspection..................................................................................................................................................................................................1400 Specifications...................................................................................................................................................................................................................1400 Tightening Torque Specifications.............................................................................................................................................................................................1400 Glass / Windows / Mirrors............................................................................................................................................................................................................1401 General Description..............................................................................................................................................................................................................1401 Rear End Door Window Defogger System Description.............................................................................................................................................................................1401 Windshield Construction......................................................................................................................................................................................................1401 Rear Quarter Window Construction.............................................................................................................................................................................................1402 Diagnostic Information and Procedures............................................................................................................................................................................................1403 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1403 Power Window Control System Symptom Diagnosis................................................................................................................................................................................1403 Power Door Mirror Control System Symptom Diagnosis (If Equipped).............................................................................................................................................................1403 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1404 Repair Instructions..............................................................................................................................................................................................................1404 Windshield Removal and Installation..........................................................................................................................................................................................1404 Rear Quarter Window Removal and Installation.................................................................................................................................................................................1407 Front Door Window Components.................................................................................................................................................................................................1411 Front Door Glass Removal and Installation....................................................................................................................................................................................1412 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1413 Front Door Window Regulator Inspection.......................................................................................................................................................................................1413 Rear Door Window Components..................................................................................................................................................................................................1414 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1414 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1415 Rear Door Window Regulator Inspection........................................................................................................................................................................................1416 Rear End Door Window Components..............................................................................................................................................................................................1416 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1416 Rear End Door Window Defogger Switch Inspection..............................................................................................................................................................................1417 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1417 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1418 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1418 Power Window Main Switch Inspection..........................................................................................................................................................................................1418 Power Window Sub Switch Inspection...........................................................................................................................................................................................1420 Door Mirror Components.......................................................................................................................................................................................................1420 Door Mirror Removal and Installation.........................................................................................................................................................................................1421 Power Door Mirror Switch Inspection (If Equipped)............................................................................................................................................................................1421 Power Door Mirror Actuator Inspection (If Equipped)..........................................................................................................................................................................1421 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1421 Special Tools and Equipment......................................................................................................................................................................................................1422 Recommended Service Material.................................................................................................................................................................................................1422 Security and Locks...................................................................................................................................................................................................................1423 General Description..............................................................................................................................................................................................................1423 Key Coding Construction......................................................................................................................................................................................................1423 Rear End Door Opener System Description......................................................................................................................................................................................1423 Component Location...............................................................................................................................................................................................................1424 Power Door Lock and Keyless Entry System Component Location..................................................................................................................................................................1424 Diagnostic Information and Procedures............................................................................................................................................................................................1425 Power Door Lock System Symptom Diagnosis.....................................................................................................................................................................................1425 Power Door Lock System Operation Inspection..................................................................................................................................................................................1425 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1426 Keyless Entry System Operation Inspection....................................................................................................................................................................................1427 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1427 Rear End Door Opener System Symptom Diagnosis................................................................................................................................................................................1427 Rear End Door Opener System Operation Inspection.............................................................................................................................................................................1427 Repair Instructions..............................................................................................................................................................................................................1428 Front Door Lock Assembly Components..........................................................................................................................................................................................1428 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1428 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1430 Power Door Lock Switch Inspection............................................................................................................................................................................................1430 Door Key Cylinder Switch Inspection..........................................................................................................................................................................................1430 Power Door Lock Actuator Inspection (If Equipped)............................................................................................................................................................................1431 Rear Door Lock Assembly Components...........................................................................................................................................................................................1432 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1432 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1432 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1433 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1433 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1434 Rear End Door Opener Switch Inspection.......................................................................................................................................................................................1434 Replacement of Transmitter Battery...........................................................................................................................................................................................1434 Programming Transmitter Code.................................................................................................................................................................................................1435 Keyless Entry Receiver Removal and Installation..............................................................................................................................................................................1435 Keyless Entry Receiver and Its Circuit Inspection............................................................................................................................................................................1436 Specifications...................................................................................................................................................................................................................1437 Tightening Torque Specifications.............................................................................................................................................................................................1437 Special Tools and Equipment......................................................................................................................................................................................................1437 Recommended Service Material.................................................................................................................................................................................................1437 Seats................................................................................................................................................................................................................................1438 Repair Instructions..............................................................................................................................................................................................................1438 Front Seat Components........................................................................................................................................................................................................1438 Front Seat Removal and Installation..........................................................................................................................................................................................1438 Rear Seat Components.........................................................................................................................................................................................................1439 Rear Seat Removal and Installation...........................................................................................................................................................................................1440 Specifications...................................................................................................................................................................................................................1441 Tightening Torque Specifications.............................................................................................................................................................................................1441 Special Tools and Equipment......................................................................................................................................................................................................1441 Recommended Service Material.................................................................................................................................................................................................1441 Interior Trim........................................................................................................................................................................................................................1442 Repair Instructions..............................................................................................................................................................................................................1442 Floor Carpet Removal and Installation........................................................................................................................................................................................1442 Head Lining Removal and Installation.........................................................................................................................................................................................1442 Console Box Components.......................................................................................................................................................................................................1444 Roof Molding Components......................................................................................................................................................................................................1444 Splash Guard (If Equipped) Components........................................................................................................................................................................................1445 Specifications...................................................................................................................................................................................................................1445 Tightening Torque Specifications.............................................................................................................................................................................................1445 Hood / Fenders / Doors...............................................................................................................................................................................................................1446 Repair Instructions..............................................................................................................................................................................................................1446 Hood Removal and Installation................................................................................................................................................................................................1446 Hood Inspection and Adjustment...............................................................................................................................................................................................1446 Front Fender Components......................................................................................................................................................................................................1447 Front Fender Removal and Installation........................................................................................................................................................................................1447 Front Door Assembly Components...............................................................................................................................................................................................1448 Front Door Assembly Removal and Installation.................................................................................................................................................................................1448 Rear Door Assembly Components................................................................................................................................................................................................1449 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1450 Rear End Door Assembly Components............................................................................................................................................................................................1450 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1450 Specifications...................................................................................................................................................................................................................1452 Tightening Torque Specifications.............................................................................................................................................................................................1452 Special Tools and Equipment......................................................................................................................................................................................................1452 Recommended Service Material.................................................................................................................................................................................................1452 Body Structure.......................................................................................................................................................................................................................1453 Repair Instructions..............................................................................................................................................................................................................1453 Front Bumper and Rear Bumper Components......................................................................................................................................................................................1453 Cowl Top Components..........................................................................................................................................................................................................1454 Specifications...................................................................................................................................................................................................................1455 Body Dimensions..............................................................................................................................................................................................................1455 Panel Clearance..............................................................................................................................................................................................................1464 Paint / Coatings.....................................................................................................................................................................................................................1465 General Description..............................................................................................................................................................................................................1465 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1465 Plastic Parts Finishing......................................................................................................................................................................................................1465 Component Location...............................................................................................................................................................................................................1466 Sealant Application Areas....................................................................................................................................................................................................1466 Under Coating Application Areas..............................................................................................................................................................................................1471 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1473 Exterior Trim........................................................................................................................................................................................................................1475 Repair Instructions..............................................................................................................................................................................................................1475 Roof Molding Components......................................................................................................................................................................................................1475 Splash Guard (If Equipped) Components........................................................................................................................................................................................1476 Control systems..........................................................................................................................................................................................................................1477 Precautions..........................................................................................................................................................................................................................1479 Precautions......................................................................................................................................................................................................................1479 Precautions for Control Systems..............................................................................................................................................................................................1479 Body Electrical Control System.......................................................................................................................................................................................................1480 Precautions......................................................................................................................................................................................................................1480 Precautions in Diagnosing Trouble............................................................................................................................................................................................1480 General Description..............................................................................................................................................................................................................1480 BCM General Description......................................................................................................................................................................................................1480 CAN Communication System Description.........................................................................................................................................................................................1480 Schematic and Routing Diagram....................................................................................................................................................................................................1482 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1482 Connector Layout Diagram of BCM and Junction Block Assembly..................................................................................................................................................................1485 Component Location...............................................................................................................................................................................................................1486 BCM and Related System Component Location....................................................................................................................................................................................1486 Diagnostic Information and Procedures............................................................................................................................................................................................1487 BCM Self-Diagnosis Function..................................................................................................................................................................................................1487 Body Electrical Control System Check.........................................................................................................................................................................................1488 Scan Tool Data...............................................................................................................................................................................................................1490 DTC Table....................................................................................................................................................................................................................1492 DTC Check....................................................................................................................................................................................................................1492 DTC Clearance................................................................................................................................................................................................................1494 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1494 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1496 DTC B1141 / DTC B1142 / DTC B1143 (No. 1141 / No. 1142/ No. 1143) Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction.........................................................................................1497 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1498 DTC B1157 (No. 1157) Air Bag Deployment Signal Input.........................................................................................................................................................................1499 DTC B1170 (No. 1170): EEPROM access error....................................................................................................................................................................................1500 DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error)......................................................................................................................................................1501 DTC U1073 (No. 1073): Control Module Communication Bus Off...................................................................................................................................................................1503 DTC U1100 (No. 1100): Lost communication with ECM............................................................................................................................................................................1505 DTC U1101 (No. 1101): Lost communication with TCM............................................................................................................................................................................1506 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1508 Inspection of BCM and its Circuits...........................................................................................................................................................................................1509 Repair Instructions..............................................................................................................................................................................................................1518 BCM (Included in Junction Block Assembly) Removal and Installation...........................................................................................................................................................1518 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1519 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1519 Special Tools and Equipment......................................................................................................................................................................................................1519 Special Tool.................................................................................................................................................................................................................1519 Immobilizer Control System...........................................................................................................................................................................................................1520 Precautions......................................................................................................................................................................................................................1520 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1520 Precaution in Replacing ECM..................................................................................................................................................................................................1520 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1520 General Description..............................................................................................................................................................................................................1521 Immobilizer Control System Introduction......................................................................................................................................................................................1521 Immobilizer Control System Components Location...............................................................................................................................................................................1521 On-Board Diagnostic System Description (Self- diagnosis Function)............................................................................................................................................................1522 Schematic and Routing Diagram....................................................................................................................................................................................................1523 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1523 Diagnostic Information and Procedures............................................................................................................................................................................................1524 Immobilizer Control System Check.............................................................................................................................................................................................1524 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1524 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1525 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1525 Scan Tool Data...............................................................................................................................................................................................................1526 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1527 Immobilizer Indicator Lamp Remains ON after Engine Starts....................................................................................................................................................................1529 DTC P1614 Transponder Response Error.........................................................................................................................................................................................1530 DTC P1615 ID Code Does Not Registered (Vehicle equipped with keyless start system only)......................................................................................................................................1531 DTC P1616 Different Registration ID Codes (Vehicle equipped with keyless start system only)..................................................................................................................................1533 DTC P1618 CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only).......................................................................................1534 DTC P1621 Immobilizer Communication Line Error...............................................................................................................................................................................1537 DTC P1622 EEPROM Error.......................................................................................................................................................................................................1539 DTC P1623 Unregistered Transponder...........................................................................................................................................................................................1540 DTC P1625 Immobilizer Antenna Error..........................................................................................................................................................................................1540 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1541 Repair Instructions..............................................................................................................................................................................................................1543 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1543 Registration of the Ignition Key.............................................................................................................................................................................................1543 Procedure after ECM Replacement..............................................................................................................................................................................................1543 Special Tools and Equipment......................................................................................................................................................................................................1544 Special Tool.................................................................................................................................................................................................................1544 Keyless Start System.................................................................................................................................................................................................................1545 General Description..............................................................................................................................................................................................................1545 Keyless Start System Description.............................................................................................................................................................................................1545 Parts and Functions..........................................................................................................................................................................................................1546 Keyless Engine Start Function................................................................................................................................................................................................1546 Door Lock Function of Keyless Start System...................................................................................................................................................................................1548 Operation Area of Remote Controller..........................................................................................................................................................................................1549 Alarm Function...............................................................................................................................................................................................................1550 CAN Communication of Keyless Start System....................................................................................................................................................................................1550 Schematic and Routing Diagram....................................................................................................................................................................................................1551 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1551 Diagnostic Information and Procedures............................................................................................................................................................................................1552 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1552 Self-Diagnosis Function......................................................................................................................................................................................................1552 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1552 Keyless Start System Check...................................................................................................................................................................................................1552 Customer questionnaire (example).............................................................................................................................................................................................1553 Key Indicator Lamp Check.....................................................................................................................................................................................................1554 DTC Check....................................................................................................................................................................................................................1554 DTC Table....................................................................................................................................................................................................................1556 DTC Clearance................................................................................................................................................................................................................1556 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1557 Keyless Start System Operation Inspection....................................................................................................................................................................................1558 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1558 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1559 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1563 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.).....................................................................................................................1565 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1567 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1568 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1569 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)..........................................................................................................1569 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1570 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1573 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1575 Repair Instructions..............................................................................................................................................................................................................1577 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1577 Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection...............................................................................................................................................1577 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1578 Steering Lock Unit Inspection................................................................................................................................................................................................1578 Front Door Lock Switch Inspection............................................................................................................................................................................................1578 Keyless start control module Removal and Installation........................................................................................................................................................................1578 Remote Controller Inspection.................................................................................................................................................................................................1579 Replacement of Remote Controller Battery.....................................................................................................................................................................................1579 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1580 COPYRIGHT................................................................................................................................................................................................................................1582
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