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SUZUKI SWIFT RS413D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI SWIFT RS413D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
SUZUKI SWIFT RS413D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 625
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI SWIFT RS413D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
START........................................................................................................ 1 IMPORTANT.................................................................................................... 1 FOREWORD..................................................................................................... 3 TABLE OF CONTENTS............................................................................................ 5 Precautions.................................................................................................. 7 Precautions.............................................................................................. 8 Precautions.......................................................................................... 8 General Precautions.............................................................................. 8 General Information.......................................................................................... 11 General Information...................................................................................... 12 General Description.................................................................................. 12 Transmission Identification Number............................................................... 12 Component Location................................................................................... 12 Warning, Caution and Information Labels Location................................................. 12 Maintenance and Lubrication.............................................................................. 14 Scheduled Maintenance................................................................................ 14 Maintenance Schedule under Normal Driving Conditions............................................. 14 Maintenance Recommended under Severe Driving Conditions.......................................... 15 Repair Instructions.................................................................................. 16 Engine accessory Drive Belt and Tensioner Inspection............................................. 16 Engine accessory Drive Belt Replacement.......................................................... 16 Engine Oil and Filter Change..................................................................... 16 Engine Coolant Change............................................................................ 18 Air Cleaner Filter Inspection.................................................................... 18 Air Cleaner Filter Replacement................................................................... 18 Fuel Lines and Connections Inspection............................................................ 18 Fuel Filter Replacement.......................................................................... 18 Water Draining of Fuel Filter.................................................................... 18 Specifications....................................................................................... 19 Tightening Torque Specifications................................................................. 19 Special Tools and Equipment.......................................................................... 19 Recommended Fluids and Lubricants................................................................ 19 Engine....................................................................................................... 21 Precautions.............................................................................................. 25 Precautions.......................................................................................... 25 Precautions for Engine........................................................................... 25 Engine General Information and Diagnosis................................................................. 26 Precautions.......................................................................................... 26 Precautions on Engine Service.................................................................... 26 Precautions in Diagnosing Trouble................................................................ 26 General Description.................................................................................. 26 Statement on Cleanliness and Care................................................................ 26 Engine Diagnosis General Description............................................................. 27 CAN Communication System Description............................................................. 28 Electronic Control System Description............................................................ 29 Schematic and Routing Diagram........................................................................ 33 Air Intake System Diagram........................................................................ 33 Component Location................................................................................... 34 Electronic Control System Components Location.................................................... 34 Diagnostic Information and Procedures................................................................ 35 DTC Check........................................................................................ 35 DTC Clearance.................................................................................... 35 A: Engine Diagnostic System Check................................................................ 36 B-01, DTC Table.................................................................................. 38 B-02, Data List.................................................................................. 41 B-03, Connect Scan Tool and Establish Communication.............................................. 47 B-04, Symptom Chart / Customer Complaints........................................................ 47 B-05, No Matching Customer Complaint............................................................. 47 B-06, Complaint: Engine Start.................................................................... 48 B-07, Complaint: Engine Idling................................................................... 48 B-08, Complaint: Engine Behavior Under Normal Driving Conditions................................. 50 B-09, Complaint: Engine Performance.............................................................. 52 B-10, Complaint: Exhaust Gas..................................................................... 54 B-11, Complaint: Oil / Coolant / Fuel-System..................................................... 55 B-12, Complaint: Engine Mechanic................................................................. 56 B-13, Check: Functionality of Adjacent Systems................................................... 56 B-14, Actuator Test.............................................................................. 57 B-15, Additional Functions....................................................................... 60 B-16, Programming................................................................................ 60 B-17, ECU Control................................................................................ 61 B-18, Check: Intermittent Faults................................................................. 62 B-19, Programming ECM............................................................................ 63 B-20, Immobilizer Check.......................................................................... 63 B-21, Fuel System................................................................................ 64 B-22, Intake-Air System.......................................................................... 64 B-23, Check: Intake-Air System................................................................... 65 B-24, Check: Intake-Air System / Charge-Air System............................................... 65 B-25, Check: Charge-Air System................................................................... 66 B-26, Check: Exhaust System...................................................................... 66 B-27, Check: Distance Signal..................................................................... 67 B-28, Check: Pressure Sensor Signal.............................................................. 67 B-29, Complaint: Engine Temperature.............................................................. 67 B-30, Check: High Pressure Area.................................................................. 68 B-31, Check: Low and High Pressure Section....................................................... 69 B-32, Check: Low Pressure Section................................................................ 69 B-33, Check: Injectors........................................................................... 70 B-34, Trouble Codes: Check 1..................................................................... 70 B-35, Trouble Codes: Check 2..................................................................... 70 B-36, Trouble Codes: Check 3..................................................................... 71 B-37, Trouble Codes: Check 4..................................................................... 71 B-38, Trouble Codes: Check 5..................................................................... 71 C-01, No Communication between Scan Tool and Control Unit........................................ 72 C-02, Control Unit Hard- and Software............................................................ 78 C-03, System Voltage Circuit..................................................................... 79 C-04, Control Unit Main Relay Circuit............................................................ 80 C-05, Crankshaft Sensor Circuit.................................................................. 84 C-06, Fuel Pump Relay Circuit.................................................................... 85 C-07, 5 V Circuit 1.............................................................................. 88 C-08, 5 V Circuit 2.............................................................................. 90 C-09, 5 V Circuit 3.............................................................................. 92 C-10, Accelerator Pedal Position (APP) Sensor Circuit............................................ 95 C-11, Barometer Sensor Circuit................................................................... 98 C-12, Boost Pressure Sensor Circuit.............................................................. 99 C-13, Intake Air Temperature Sensor Circuit......................................................101 C-14, Mass or Volume Air Flow Circuit............................................................102 C-15, Engine Coolant Temperature Sensor Circuit..................................................105 C-16, Fuel Temperature Sensor Circuit............................................................107 C-17, Fuel Rail Pressure Sensor Circuit..........................................................109 C-18, Rail Oil Pressure Sensor Circuit...........................................................111 C-19, Fuel Rail Pressure Control Valve Circuit...................................................112 C-20, Camshaft Position Sensor Circuit...........................................................114 C-21, Brake Switch Circuit.......................................................................116 C-22, Clutch Switch Circuit......................................................................121 C-23, Injector Circuit...........................................................................122 C-24, Cylinder 1 Injector Circuit................................................................122 C-25, Cylinder 2 Injector Circuit................................................................124 C-26, Cylinder 3 Injector Circuit................................................................126 C-27, Cylinder 4 Injector Circuit................................................................128 C-28, Exhaust Gas Recirculation Valve Circuit....................................................131 C-29, Air Conditioning System Refrigerant Pressure Sensor........................................133 C-30, Engine Oil Pressure Switch Circuit.........................................................136 C-31, Air Conditioning System Relay Circuit......................................................137 C-32, Fan Circuit................................................................................140 C-33, Glow Time Relay Circuit....................................................................147 C-34, CAN Communication Circuit..................................................................150 C-35, Filter heating Circuit.....................................................................154 C-36, Malfunction Indicator Lamp (MIL) Circuit...................................................158 C-37, Vehicle Speed Sensor Circuit...............................................................160 C-38, Function-Group Intake Air System...........................................................161 C-39, Function-Group Fuel System.................................................................162 C-40, Function-Group Low Pressure Section........................................................162 C-41, Function-Group Low and High Pressure Section...............................................163 C-42, Function-Group High Pressure Area..........................................................163 C-43, Starter Circuit............................................................................164 C-44, System Status Information..................................................................169 Special Tools and Equipment..........................................................................169 Special Tool.....................................................................................169 Aux. Emission Control Devices............................................................................170 Repair Instructions..................................................................................170 Vacuum Pump Removal and Installation.............................................................170 EGR Valve Assembly Components....................................................................171 EGR Valve Assembly Removal and Installation......................................................172 Crankcase Ventilation System Component...........................................................173 Oil Separator and Crankcase Ventilation Cover Removal and Installation...........................173 Specifications.......................................................................................174 Tightening Torque Specifications.................................................................174 Engine Electrical Devices................................................................................175 Repair Instructions..................................................................................175 Idle Speed Inspection............................................................................175 Engine Control Module (ECM) Removal and Installation.............................................175 ECM Registration.................................................................................175 Registration Data Check..........................................................................176 Mass Air Flow (MAF) and Intake Air Temperature Sensor Removal and Installation...................176 Glow Plug Removal and Installation...............................................................177 Accelerator Pedal Position (APP) Sensor Components...............................................178 Accelerator Pedal Position (APP) Sensor Removal and Installation.................................178 Accelerator Pedal Position (APP) Sensor Inspection...............................................179 Engine Coolant Temperature (ECT) Sensor Removal and Installation.................................180 Camshaft Position (CMP) Sensor Removal and Installation..........................................180 Crankshaft Position (CKP) Sensor (Engine Speed Sensor) Removal and Installation..................181 Boost Pressure Sensor Removal and Installation...................................................181 Fuel Pump Relay, Starting Motor Control Relay, Main Relay and Fuel Heating Relay Inspection......182 Glow Controller Removal and Installation.........................................................182 Specifications.......................................................................................183 Tightening Torque Specifications.................................................................183 Special Tools and Equipment..........................................................................183 Special Tool.....................................................................................183 Engine Mechanical........................................................................................184 Diagnostic Information and Procedures................................................................184 Compression Check................................................................................184 Timing Check.....................................................................................185 Repair Instructions..................................................................................186 Air Cleaner Components...........................................................................186 Air Cleaner Filter Removal and Installation......................................................187 Air Cleaner Filter Inspection and Cleaning.......................................................187 Air Cleaner Assembly Removal and Installation....................................................187 Intercooler Components...........................................................................188 Intercooler Removal and Installation.............................................................189 Turbocharger Components..........................................................................190 Turbocharger Removal and Installation............................................................191 Turbocharger Inspection..........................................................................194 Intake Manifold Components.......................................................................195 Intake Manifold Removal and Installation.........................................................195 Engine Mounting Components.......................................................................197 Engine Assembly Removal and Installation.........................................................198 Timing Chain Cover and Timing Chain Components...................................................201 Timing Chain Cover and Timing Chain Removal and Installation.....................................202 Timing Chain Cover and Timing Chain Inspection...................................................208 Camshaft Housing Components......................................................................209 Camshaft Housing Assembly Removal and Installation...............................................210 Camshaft Housing Assembly Disassembly and Reassembly.............................................212 Camshaft Inspection..............................................................................214 Valves and Cylinder Head Components..............................................................216 Valves and Cylinder Head Assembly Removal and Installation.......................................217 Valves and Cylinder Head Assembly Disassembly and Reassembly.....................................220 Valves and Cylinder Head Components Inspection...................................................222 Pistons, Piston Rings, Connecting Rods and Cylinder Components...................................223 Pistons, Piston Rings, Connecting Rods and Cylinder Removal and Installation.....................224 Pistons, Piston Rings, Connecting Rods and Cylinder Disassembly and Reassembly...................226 Pistons, Piston Rings, Connecting Rods and Cylinder Inspection...................................227 Main Bearings, Crankshaft and Cylinder Block Components..........................................230 Main Bearings, Crankshaft and Cylinder Block Removal and Installation............................231 Main Bearings, Crankshaft and Cylinder Block Inspection..........................................235 Specifications.......................................................................................236 Tightening Torque Specifications.................................................................236 Special Tools and Equipment..........................................................................238 Recommended Service Material.....................................................................238 Special Tool.....................................................................................238 Engine Lubrication System................................................................................240 Diagnostic Information and Procedures................................................................240 Oil Pressure Check...............................................................................240 Repair Instructions..................................................................................241 Oil Pressure Switch Removal and Installation.....................................................241 Oil Cooler Components............................................................................241 Oil Cooler Removal and Installation..............................................................242 Oil Pan Components...............................................................................243 Oil Pan Removal and Installation.................................................................243 Oil Pump / Oil Pump Strainer Components..........................................................245 Oil Pump / Oil Pump Strainer Removal and Installation............................................246 Oil Pump Strainer Cleaning.......................................................................246 Oil Pump Inspection..............................................................................246 Specifications.......................................................................................247 Tightening Torque Specifications.................................................................247 Special Tools and Equipment..........................................................................247 Recommended Service Material.....................................................................247 Special Tool.....................................................................................247 Engine Cooling System....................................................................................248 General Description..................................................................................248 Cooling System Description.......................................................................248 Coolant Description..............................................................................248 Coolant Degassing Tank Description...............................................................248 Schematic and Routing Diagram........................................................................249 Coolant Circulation..............................................................................249 Diagnostic Information and Procedures................................................................250 Engine Cooling Symptom Diagnosis.................................................................250 Radiator Fan Control System Inspection...........................................................250 Repair Instructions..................................................................................251 Cooling System Components........................................................................251 Coolant Level Check..............................................................................252 Engine Cooling System Inspection and Cleaning....................................................252 Cooling System Draining..........................................................................253 Cooling System Refill............................................................................253 Cooling System Flush and Refill..................................................................253 Cooling Water Pipes or Hoses Removal and Installation............................................254 Thermostat Case Assembly Removal and Installation................................................254 Radiator Cooling Fan Assembly On-Vehicle Inspection..............................................255 Radiator Cooling Fan Relay Inspection............................................................255 Radiator Cooling Fan Assembly Removal and Installation...........................................256 Radiator On-Vehicle Inspection and Cleaning......................................................256 Radiator Removal and Installation................................................................257 Water Pump / Generator Drive Belt Tension Inspection.............................................257 Water Pump / Generator Drive Belt Removal and Installation.......................................258 Water Pump / Generator Drive Belt Tensioner Assembly Removal and Installation....................258 Water Pump Removal and Installation..............................................................259 Water Pump Inspection............................................................................259 Specifications.......................................................................................260 Tightening Torque Specifications.................................................................260 Fuel System..............................................................................................261 Precautions..........................................................................................261 Precautions on Fuel System Service...............................................................261 General Description..................................................................................263 Fuel System Description..........................................................................263 Schematic and Routing Diagram........................................................................264 Fuel Delivery System Diagram.....................................................................264 Repair Instructions..................................................................................265 Fuel Hose Disconnecting and Reconnecting.........................................................265 Fuel Leakage Check Procedure.....................................................................267 Water Draining of Fuel Filter....................................................................267 Air Bleeding of Fuel System......................................................................267 Fuel Delivery System (High Pressure) Components..................................................268 Fuel Injector On-Vehicle Inspection..............................................................269 Fuel Injector Removal and Installation...........................................................269 Common Rail (High Pressure Fuel Injection Rail) Removal and Installation.........................272 Injection Pump Removal and Installation..........................................................273 Fuel Pressure Sensor Removal and Installation....................................................274 Fuel Pressure Regulator Removal and Installation.................................................275 Fuel Pressure Regulator Inspection...............................................................275 Fuel Delivery System (Low Pressure) Components...................................................276 Fuel Lines On-Vehicle Inspection.................................................................277 Fuel Pipe Removal and Installation...............................................................277 Fuel Filler Cap Inspection.......................................................................278 Fuel Tank Removal and Installation...............................................................278 Fuel Tank Inspection.............................................................................280 Fuel Tank Purging Procedure......................................................................281 Fuel Pump On-Vehicle Inspection..................................................................281 Fuel Pump Assembly Removal and Installation......................................................281 Fuel Pump Inspection.............................................................................282 Fuel Filter Element Removal and Installation.....................................................283 Fuel Filter Assembly Removal and Installation....................................................284 Fuel Heater and Temperature Sensor Removal and Installation......................................284 Fuel Temperature Sensor Inspection...............................................................285 Specifications.......................................................................................285 Tightening Torque Specifications.................................................................285 Special Tools and Equipment..........................................................................286 Special Tool.....................................................................................286 Starting System..........................................................................................287 General Description..................................................................................287 Cranking System Description......................................................................287 Schematic and Routing Diagram........................................................................287 Cranking System Circuit Diagram..................................................................287 Diagnostic Information and Procedures................................................................288 Cranking System Symptom Diagnosis................................................................288 Cranking System Test.............................................................................289 Repair Instructions..................................................................................290 Starting Motor Dismounting and Remounting........................................................290 Specifications.......................................................................................291 Tightening Torque Specifications.................................................................291 Charging System..........................................................................................292 General Description..................................................................................292 Generator Description............................................................................292 Diagnostic Information and Procedures................................................................293 Battery Inspection...............................................................................293 Generator Symptom Diagnosis......................................................................294 Generator Test (Undercharged Battery Check)......................................................295 Generator Test (Overcharged Battery Check).......................................................295 Repair Instructions..................................................................................296 Battery Dismounting and Remounting...............................................................296 Generator Dismounting and Remounting.............................................................296 Specifications.......................................................................................297 Charging System Specifications...................................................................297 Tightening Torque Specifications.................................................................297 Exhaust System...........................................................................................298 General Description..................................................................................298 Exhaust System Description.......................................................................298 Diagnostic Information and Procedures................................................................298 Exhaust System Check.............................................................................298 Repair Instructions..................................................................................299 Exhaust System Components........................................................................299 Exhaust Manifold Components......................................................................300 Exhaust Manifold Removal and Installation........................................................301 Exhaust Manifold Inspection......................................................................302 Catalytic Converter Removal and Installation.....................................................302 Exhaust Pipe and Muffler Removal and Installation................................................302 Specifications.......................................................................................302 Tightening Torque Specifications.................................................................302 Suspension...................................................................................................303 Front Suspension.........................................................................................305 Repair Instructions..................................................................................305 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation..................305 Driveline / Axle.............................................................................................309 Drive Shaft / Axle.......................................................................................310 General Description..................................................................................310 Front Drive Shaft Construction...................................................................310 Component Location...................................................................................310 Front Drive Shaft Assembly Components Location...................................................310 Diagnostic Information and Procedures................................................................311 Front Drive Shaft Symptom Diagnosis..............................................................311 Repair Instructions..................................................................................311 Front Drive Shaft Components.....................................................................311 Front Drive Shaft Assembly On-Vehicle Inspection.................................................312 Front Drive Shaft Assembly Removal and Installation..............................................312 Front Drive Shaft Disassembly and Assembly.......................................................313 Center Shaft and Center Bearing Support Disassembly and Assembly.................................318 Specifications.......................................................................................319 Tightening Torque Specifications.................................................................319 Special Tools and Equipment..........................................................................319 Recommended Service Material.....................................................................319 Special Tool.....................................................................................319 Brakes.......................................................................................................321 ABS......................................................................................................323 General Description..................................................................................323 ABS Hydraulic Unit / Control Module Assembly Description.........................................323 Schematic and Routing Diagram........................................................................324 ABS Schematic....................................................................................324 ABS Wiring Circuit Diagram.......................................................................325 Diagnostic Information and Procedures................................................................327 Serial Data Link Circuit Check...................................................................327 Repair Instructions..................................................................................329 Rear Wheel Speed Sensor Removal and Installation.................................................329 Vehicle Speed Output Signal Inspection...........................................................330 Transmission / Transaxle.....................................................................................331 Manual Transmission......................................................................................332 General Description..................................................................................332 Manual Transaxle Construction and Servicing......................................................332 Diagnostic Information and Procedures................................................................334 Manual Transaxle Symptom Diagnosis...............................................................334 Repair Instructions..................................................................................335 Manual Transaxle Oil Change......................................................................335 Differential Side Oil Seal Replacement...........................................................336 Gear Shift Control Lever and Cable Components....................................................337 Gear Shift Control Lever and Cable Removal and Installation......................................338 Back Up Lamp Switch Removal and Installation.....................................................339 Back Up Lamp Switch Inspection...................................................................339 Manual Transaxle Unit Components.................................................................340 Manual Transaxle Unit Dismounting and Remounting.................................................341 Manual Transaxle Assembly Components.............................................................343 Selector Lever Assembly Removal and Installation.................................................344 5th Gears Removal and Installation...............................................................345 Gear Selector, Cluster Gear and Main Shaft Components............................................347 Gear Selector, Cluster Gear and Main Shaft Removal and Installation..............................348 Transaxle Case Disassembly and Assembly..........................................................352 Counter Gear and Main Shaft Components...........................................................355 Main Shaft Disassembly and Assembly..............................................................356 Cluster Gear and Main Shaft Inspection...........................................................358 Differential Components..........................................................................359 Differential Disassembly and Assembly............................................................359 Differential Adjustment..........................................................................361 Specifications.......................................................................................362 Tightening Torque Specifications.................................................................362 Special Tools and Equipment..........................................................................363 Recommended Service Material.....................................................................363 Special Tool.....................................................................................363 Clutch...................................................................................................366 General Description..................................................................................366 Clutch (Hydraulic Type) Construction.............................................................366 Diagnostic Information and Procedures................................................................367 Clutch System Symptom Diagnosis..................................................................367 Repair Instructions..................................................................................368 Clutch Pedal Inspection..........................................................................368 Clutch Fluid Level Inspection....................................................................368 Air Bleeding of Clutch System....................................................................368 Clutch Fluid Pipe and Hose Location..............................................................369 Clutch Fluid Pipe Removal and Installation.......................................................369 Clutch Fluid Pipe Inspection.....................................................................369 Clutch Master Cylinder Removal and Installation..................................................370 Clutch Operating Cylinder Assembly Removal and Installation......................................370 Clutch Pedal and Clutch Pedal Bracket Components.................................................372 Clutch Cover and Clutch Disc Components..........................................................373 Clutch Cover and Clutch Disc Removal and Installation............................................373 Clutch Cover and Clutch Disc Inspection..........................................................375 Specifications.......................................................................................375 Tightening Torque Specifications.................................................................375 Special Tools and Equipment..........................................................................376 Recommended Service Material.....................................................................376 Special Tool.....................................................................................376 Steering.....................................................................................................377 Power Assisted Steering System...........................................................................379 General Description..................................................................................379 P/S System Description...........................................................................379 Schematic and Routing Diagram........................................................................380 EPS System Wiring Circuit Diagram................................................................380 Diagnostic Information and Procedures................................................................381 DTC Table........................................................................................381 Scan Tool Data...................................................................................383 P/S System Symptom Diagnosis.....................................................................384 Serial Data Link Circuit Check...................................................................384 DTC C1121 / C1123 / C1124: VSS Circuit Failure...................................................386 DTC C1122: Engine Speed Signal Circuit Failure...................................................388 Inspection of P/S Control Module and Its Circuits................................................389 Specifications.......................................................................................391 Tightening Torque Specifications.................................................................391 Special Tools and Equipment..........................................................................392 Recommended Service Material.....................................................................392 Special Tool.....................................................................................392 HVAC.........................................................................................................393 Heater and Ventilation...................................................................................395 General Description..................................................................................395 Heater and Ventilation Construction..............................................................395 Supplementary Heater System Description (If Equipped)............................................396 Supplementary Heater System Components Location..................................................396 Supplementary Heater System Electronic Input / Output Table......................................397 On-Board Diagnostic System Description (Vehicle Equipped with Supplementary Heater)..............397 Schematic and Routing Diagram........................................................................398 Heater and Ventilation Wiring Circuit Diagram....................................................398 Diagnostic Information and Procedures................................................................399 Heater and Ventilation Symptom Diagnosis.........................................................399 DTC Check for Supplementary Heater System........................................................400 DTC Clearance for Supplementary Heater System....................................................400 DTC Table for Supplementary Heater System........................................................400 Scan Tool Data...................................................................................401 DTC B1536: Supplementary Heater Relay No.1 Output Malfunction....................................402 DTC B1537: Supplementary Heater Relay No.2 and No.3 Output Malfunction...........................403 DTC B1541: Supplementary Heater Controller Back-Up Power Supply Malfunction......................404 DTC B1542: Blower Motor Power Supply Malfunction.................................................405 DTC B1551: Serial Communication Circuit Malfunction..............................................407 DTC B1552: Serial Communication Data Malfunction.................................................408 DTC B1553: CAN Communication Circuit Malfunction.................................................408 DTC B1556: Engine Speed Data Malfunction.........................................................409 DTC B1557: Vehicle Speed Data Malfunction........................................................409 DTC B1559: Ignition Power Supply Voltage Data Malfunction........................................409 DTC B1561: Engine Coolant Temperature Data Malfunction...........................................410 DTC B1562: Outside Air Temperature Data Malfunction..............................................410 Inspection of Supplementary Heater Controller and Its Circuit (If Equipped)......................411 Repair Instructions..................................................................................413 HVAC Unit Components.............................................................................413 Blower Motor Resistor Inspection.................................................................414 Blower Motor Relay and Supplementary Heater Relay (If Equipped) Inspection.......................414 Supplementary Heater Removal and Installation (If Equipped)......................................415 Supplementary Heater Inspection (If Equipped)....................................................415 Supplementary Heater Controller Removal and Installation (If Equipped)...........................416 Max Hot Switch Removal and Installation (If Equipped)............................................416 Max Hot Switch Inspection (If Equipped)..........................................................416 Air Intake Control Actuator Removal and Installation.............................................417 Specifications.......................................................................................417 Tightening Torque Specifications.................................................................417 Special Tools and Equipment..........................................................................417 Special Tool.....................................................................................417 Air Conditioning System..................................................................................418 Precautions..........................................................................................418 Precautions on Servicing A/C System..............................................................418 General Description..................................................................................419 Sub-Cool A/C System Description..................................................................419 A/C Operation Description........................................................................420 Schematic and Routing Diagram........................................................................420 A/C System Wiring Diagram........................................................................420 Diagnostic Information and Procedures................................................................422 A/C System Symptom Diagnosis.....................................................................422 Abnormal Noise Symptom Diagnosis of A/C System...................................................424 A/C System Performance Inspection................................................................425 Repair Instructions..................................................................................430 Operation Procedure for Refrigerant Charge.......................................................430 Desiccant Removal and Installation...............................................................435 HVAC Unit Components.............................................................................436 HVAC Unit Removal and Installation...............................................................437 Compressor Relay Inspection......................................................................438 Compressor Drive Belt Inspection and Adjustment..................................................438 Compressor Drive Belt Removal and Installation...................................................438 Compressor Assembly Removal and Installation.....................................................438 Magnet Clutch Inspection.........................................................................439 Relief Valve Inspection..........................................................................439 Specifications.......................................................................................439 Tightening Torque Specifications.................................................................439 Special Tools and Equipment..........................................................................440 Recommended Service Material.....................................................................440 Special Tool.....................................................................................440 Body, Cab and Accessories....................................................................................441 Wiring Systems...........................................................................................446 Precautions..........................................................................................446 Cautions in Body Electrical System Servicing.....................................................446 Precautions for Wiring System....................................................................446 General Description..................................................................................447 Abbreviations....................................................................................447 Wire / Connector Color Symbols...................................................................447 Symbols and Marks................................................................................448 How to Read Connector Layout Diagram.............................................................449 How to Read Connector Codes and Terminal Nos.....................................................450 How to Read Ground Point.........................................................................453 How to Read Power Supply Diagram.................................................................454 How to Read System Circuit Diagram...............................................................454 Harness Routing and Connector Layout Diagram.........................................................456 Connector Layout Diagram.........................................................................456 Engine Compartment...............................................................................456 E: Main harness (RHD) (DSL)......................................................................462 E: Main harness (LHD) (DSL)......................................................................463 Instrument Panel.................................................................................464 Door, Roof.......................................................................................468 Floor............................................................................................470 Rear.............................................................................................478 Ground Point.........................................................................................479 Ground (earth) Point.............................................................................479 Power Supply Diagram.................................................................................480 Power Supply Diagram (Petrol)....................................................................480 Power Supply Diagram (DSL).......................................................................481 Fuses and the Protected Parts....................................................................482 Fuses in Main Fuse Box (Petrol)..................................................................482 Fuses in Main Fuse Box (DSL).....................................................................482 Individual Circuit Fuse Box No. 1 (Petrol).......................................................483 Individual Circuit Fuse Box No. 1 (DSL)..........................................................483 Individual Circuit Fuse Box No. 3 (DSL)..........................................................484 Individual Circuit Fuse Box No. 2 (In J/B).......................................................485 Junction Block (J/B) Connector / Fuse Layout.....................................................487 Junction Block Inner Circuit (Overview)..........................................................489 Junction Block Inner Circuit (Detail)............................................................490 System Circuit Diagram...............................................................................495 System Circuit Diagram...........................................................................495 A-1 Cranking System Circuit Diagram (Petrol).....................................................496 A-1 Cranking System Circuit Diagram (DSL)........................................................497 A-2 Charging System Circuit Diagram (Petrol).....................................................498 A-2 Charging System Circuit Diagram (DSL)........................................................499 A-3 Ignition System Circuit Diagram (Petrol).....................................................500 A-4 Cooling System Circuit Diagram (Petrol)......................................................501 A-4 Cooling System Circuit Diagram (DSL).........................................................502 A-5 Engine and A/C Control System Circuit Diagram (Petrol).......................................503 A-5 Engine and A/C Control System (DSL)..........................................................508 A-6 A/T Control System Circuit Diagram...........................................................513 A-7 Immobilizer System Circuit Diagram (Petrol)..................................................515 A-7 Immobilizer System Circuit Diagram (DSL).....................................................516 A-8 Body Control System Circuit Diagram..........................................................517 A-9 Automated Manual Transaxle Control System Circuit Diagram (Petrol)...........................521 B-1 Windshield Wiper and Washer Circuit Diagram..................................................524 B-2 Rear Wiper and Washer Circuit Diagram........................................................525 B-3 Rear Defogger Circuit Diagram................................................................526 B-4 Power Window Circuit Diagram.................................................................527 B-5 Power Door Lock Circuit Diagram..............................................................528 B-6 Power Mirror Circuit Diagram.................................................................530 B-7 Horn Circuit Diagram.........................................................................531 B-8 Seat Heater Circuit Diagram..................................................................532 B-9 Smart Key System Circuit Diagram.............................................................533 C-1 Combination Meter Circuit Diagram (Meter)....................................................534 C-2 Combination Meter Circuit Diagram (Indicator)................................................535 C-3 Combination Meter Circuit Diagram (Warning Light)............................................536 D-1 Headlight System Circuit Diagram.............................................................538 D-2 Position, Tail and Licence Plate Light System Circuit Diagram................................540 D-3 Front Fog Light System Circuit Diagram.......................................................541 D-4 Illumination Light System Circuit Diagram....................................................542 D-5 Interior Light System Circuit Diagram........................................................543 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..................................544 D-7 Brake Light System Circuit Diagram...........................................................546 D-8 Back-Up Light System Circuit Diagram.........................................................547 D-9 Headlight Beam Leveling System Circuit Diagram...............................................548 D-10 Rear Fog Light Circuit Diagram..............................................................549 E-1 Heater System Circuit Diagram................................................................550 E-3 PTC Heater Circuit Diagram (DSL).............................................................552 F-1 Air-Bag System Circuit Diagram...............................................................554 F-2 Anti-Lock Brake System Circuit Diagram.......................................................556 F-3 Power Steering System Circuit Diagram........................................................558 G-1 Audio System Circuit Diagram.................................................................560 G-2 Multi Information Display / Accessory Socket System Circuit Diagram..........................561 G-4 Navigation System Circuit Diagram............................................................562 List of Connectors...................................................................................563 List of Connectors...............................................................................563 C Connector......................................................................................563 D Connector (DSL)................................................................................564 E Connector......................................................................................565 G Connector......................................................................................567 J Connector......................................................................................569 K Connector......................................................................................569 L Connector......................................................................................570 O Connector......................................................................................572 R Connector......................................................................................572 Instrumentation / Driver Info. / Horn....................................................................573 General Description..................................................................................573 CAN Communication Data of Combination Meter......................................................573 Schematic and Routing Diagram........................................................................574 Combination Meter Circuit Diagram................................................................574 Diagnostic Information and Procedures................................................................575 Speedometer and VSS Symptom Diagnosis............................................................575 Information Display Symptom Diagnosis (If Equipped)..............................................576 Repair Instructions..................................................................................577 Oil Pressure Switch Removal and Installation.....................................................577 Oil Pressure Switch Inspection...................................................................577 VSS Removal and Installation.....................................................................577 VSS Inspection...................................................................................577 Control systems..............................................................................................579 Body Electrical Control System...........................................................................581 General Description..................................................................................581 CAN Communication System Description.............................................................581 Schematic and Routing Diagram........................................................................582 Body Electrical Control System Wiring Circuit Diagram............................................582 Component Location...................................................................................585 BCM and Related System Component Location........................................................585 Diagnostic Information and Procedures................................................................586 BCM Self-Diagnosis Function......................................................................586 Scan Tool Data...................................................................................587 DTC Table........................................................................................589 DTC B1133 (DTC No. 1133): Battery Voltage Too High...............................................590 DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error)..........................591 DTC U1073 (No. 1073): Control Module Communication Bus Off.......................................593 DTC U1100 (No. 1100): Lost communication with ECM................................................595 Inspection of BCM and its Circuits...............................................................596 Immobilizer Control System...............................................................................605 Precautions..........................................................................................605 Precautions in Diagnosing Troubles...............................................................605 Precautions in Handling Immobilizer Control System...............................................605 General Description..................................................................................606 Immobilizer Control System Operation Description.................................................606 Immobilizer Control System Components Description................................................606 On-Board Diagnostic System Description...........................................................607 Schematic and Routing Diagram........................................................................608 Immobilizer Control System Wiring Circuit Diagram................................................608 Diagnostic Information and Procedures................................................................609 Immobilizer Control System Check.................................................................609 DTC Check........................................................................................609 DTC Clearance....................................................................................610 DTC Table........................................................................................610 Scan Tool Data...................................................................................611 SVS Lamp Does Not Come ON with Ignition Switch ON and Engine Stop................................612 SVS Lamp Remains On after Ignition Switch ON.....................................................614 DTC B3040: W-Line Communication Failure..........................................................614 DTC B3042: W-Line Circuit Malfunction Shorted to Ground..........................................615 DTC B3043: W-Line Circuit Malfunction Shorted to Battery.........................................615 DTC B3055: No Transponder........................................................................616 DTC B3056: No Fix Code Registered................................................................617 DTC B3057: No Password Registered................................................................617 DTC B3059: No Request from ECM...................................................................618 DTC B3060: Incorrect Transponder Detected........................................................618 DTC B3061: Transponder Communication Failure.....................................................619 DTC P1610: Secret Key / Password Not Programed...................................................619 DTC P1611: Password Is Not Matched...............................................................620 DTC P1612 / P1613: No Signal from Immobilizer Control Module / Immobilizer System Malfunction....620 DTC P1614: Incorrect Signal from Immobilizer Control Module......................................621 Registration Procedure of Immobilizer Control System Components..................................621 Inspection of Immobilizer Control Module and Its Circuit.........................................622 Repair Instructions..................................................................................623 Immobilizer Control Module Removal and Installation..............................................623 Procedure after Immobilizer Control Module Replacement...........................................623 Procedure after ECM Replacement..................................................................623 Special Tools and Equipment..........................................................................624 Special Tool.....................................................................................624 COPYRIGHT....................................................................................................625
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