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Suzuki Swift RS416 Service Manual (VOL 1&2) – PDF DOWNLOAD
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Description
Suzuki Swift RS416 Service Manual (VOL 1&2) – PDF DOWNLOAD
FILE DETAILS:
Suzuki Swift RS416 Service Manual (VOL 1&2) – PDF DOWNLOAD
Language : English
Pages : 1440
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki Swift RS416 Service Manual (VOL 1&2) – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and reassembly of major components (Unit Repair Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
- VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 5 – 10).
Applicable Model:
SWIFT (RS416) vehicles produced at KOSAI plant in Japan with the following vehicle identification numbers (VINs). - The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work.
- Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki Swift RS416 Service Manual (VOL 1&2) – PDF DOWNLOAD
TOP...................................................................................................................................................................................................................................... 0 MANUAL LIST.............................................................................................................................................................................................................................. 0 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.......................................................................................................................................................................................................... 11 Warning for Wheel (with tire) Removal........................................................................................................................................................................................ 13 Warning for Handling Emergency Flat Tire Repair Kit.......................................................................................................................................................................... 13 Precautions for Catalytic Converter.......................................................................................................................................................................................... 13 Precautions for Installing Mobile Communication Equipment.................................................................................................................................................................... 14 Precaution for CAN Communication System...................................................................................................................................................................................... 14 Precautions for Electrical Circuit Service................................................................................................................................................................................... 14 Air Bag Warning.............................................................................................................................................................................................................. 16 Air Bag System Service Warning............................................................................................................................................................................................... 16 Fastener Caution............................................................................................................................................................................................................. 17 Suspension Caution........................................................................................................................................................................................................... 17 Wheels and Tires Caution..................................................................................................................................................................................................... 17 Brake Caution................................................................................................................................................................................................................ 17 Repair Instructions.............................................................................................................................................................................................................. 18 Electrical Circuit Inspection Procedure...................................................................................................................................................................................... 18 Intermittent and Poor Connection Inspection.................................................................................................................................................................................. 20 General Information...................................................................................................................................................................................................................... 21 General Information.................................................................................................................................................................................................................. 22 General Description.............................................................................................................................................................................................................. 22 Abbreviations................................................................................................................................................................................................................ 22 Symbols...................................................................................................................................................................................................................... 23 Wire Color Symbols........................................................................................................................................................................................................... 24 Fasteners Information........................................................................................................................................................................................................ 24 Vehicle Lifting Points....................................................................................................................................................................................................... 26 Engine Supporting Points..................................................................................................................................................................................................... 28 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...................................................................................................................................................................................................... 37 Fuel Tank Inspection......................................................................................................................................................................................................... 37 PCV Valve Inspection......................................................................................................................................................................................................... 37 Fuel Evaporative Emission Control System Inspection.......................................................................................................................................................................... 37 Brake Discs and Pads Inspection.............................................................................................................................................................................................. 37 Brake Hoses and Pipes Inspection............................................................................................................................................................................................. 37 Brake Fluid Replacement...................................................................................................................................................................................................... 38 Brake Lever and Cable Inspection............................................................................................................................................................................................. 38 Clutch Fluid Inspection...................................................................................................................................................................................................... 38 Tires Inspection............................................................................................................................................................................................................. 38 Wheel Discs Inspection....................................................................................................................................................................................................... 38 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........................................................................................................................................................................................ 40 Automatic Transaxle Fluid Cooler Hose Inspection............................................................................................................................................................................. 41 All Latches, Hinges and Locks Inspection..................................................................................................................................................................................... 41 HVAC Air Filter (If Equipped) Inspection..................................................................................................................................................................................... 41 HVAC Air Filter (If Equipped) Replacement.................................................................................................................................................................................... 41 Final Inspection for Maintenance Service..................................................................................................................................................................................... 41 Specifications................................................................................................................................................................................................................... 43 Tightening Torque Specifications............................................................................................................................................................................................. 43 Special Tools and Equipment...................................................................................................................................................................................................... 43 Recommended Fluids and Lubricants............................................................................................................................................................................................ 43 Special Tool................................................................................................................................................................................................................. 43 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..................................................................................................................................................................... 52 General Description.............................................................................................................................................................................................................. 52 Statement on Cleanliness and Care............................................................................................................................................................................................ 52 Engine Diagnosis General Description......................................................................................................................................................................................... 53 On-Board Diagnostic System Description....................................................................................................................................................................................... 53 Engine and Emission Control System Description............................................................................................................................................................................... 56 CAN Communication System Description......................................................................................................................................................................................... 56 Air Intake System Description................................................................................................................................................................................................ 58 Description of Electric Throttle Body System................................................................................................................................................................................. 59 Description of Electric Throttle Body System Calibration..................................................................................................................................................................... 60 Fuel Cut Control Description................................................................................................................................................................................................. 60 Generator Control System Description......................................................................................................................................................................................... 60 Electronic Control System Description........................................................................................................................................................................................ 61 Engine and Emission Control Input / Output Table............................................................................................................................................................................. 67 Schematic and Routing Diagram.................................................................................................................................................................................................... 68 Engine and Emission Control System Diagram................................................................................................................................................................................... 68 Component Location............................................................................................................................................................................................................... 70 Electronic Control System Components Location................................................................................................................................................................................ 70 Diagnostic Information and Procedures............................................................................................................................................................................................ 71 Engine and Emission Control System Check..................................................................................................................................................................................... 71 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 74 DTC Check.................................................................................................................................................................................................................... 75 DTC Clearance................................................................................................................................................................................................................ 76 DTC Table.................................................................................................................................................................................................................... 76 Fail-Safe Table.............................................................................................................................................................................................................. 81 Scan Tool Data............................................................................................................................................................................................................... 83 Visual Inspection............................................................................................................................................................................................................ 87 Engine Basic Inspection...................................................................................................................................................................................................... 88 Engine Symptom Diagnosis..................................................................................................................................................................................................... 91 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)..................................................................................................................................... 97 Malfunction Indicator Lamp Remains ON after Engine Starts.................................................................................................................................................................... 98 DTC P0010: “A” Camshaft Position Actuator Circuit............................................................................................................................................................................ 99 DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System Performance / - Retarded........................................................................................................................... 102 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)......................................................................................................................................................... 104 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)......................................................................................................................................................... 106 DTC P0101: Mass or Volume Air Flow Circuit Range / Performance............................................................................................................................................................... 108 DTC P0102: Mass or Volume Air Flow Circuit Low Input......................................................................................................................................................................... 111 DTC P0103: Mass or Volume Air Flow Circuit High Input........................................................................................................................................................................ 113 DTC P0106: Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance...................................................................................................................................... 114 DTC P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low Input................................................................................................................................................ 116 DTC P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High Input............................................................................................................................................... 117 DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance....................................................................................................................................................... 119 DTC P0112: Intake Air Temperature Sensor 1 Circuit Low....................................................................................................................................................................... 122 DTC P0113: Intake Air Temperature 1 Sensor Circuit High...................................................................................................................................................................... 124 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................................................................................................ 126 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................................................................................................ 129 DTC P0118: Engine Coolant Temperature Circuit High........................................................................................................................................................................... 131 DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low.................................................................................................................................................. 133 DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit High................................................................................................................................................. 135 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................................................................................................ 138 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)................................................................................................................................................................. 141 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1).......................................................................................................................................................... 142 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................................................................................................ 144 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2).......................................................................................................................................................... 147 DTC P0171 / P0172: Fuel System Too Lean / Rich............................................................................................................................................................................... 149 DTC P0222: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit Low................................................................................................................................................... 151 DTC P0223: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit High.................................................................................................................................................. 153 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected.................................................................. 156 DTC P0327 / P0328: Knock Sensor 1 Circuit Low / High......................................................................................................................................................................... 158 DTC P0335: Crankshaft Position (CKP) Sensor “A” Circuit...................................................................................................................................................................... 160 DTC P0340: Camshaft Position (CMP) Sensor “A” Circuit........................................................................................................................................................................ 162 DTC P0350: Ignition Coil Primary / Secondary Circuit......................................................................................................................................................................... 165 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected................................................................................................................................. 167 DTC P0403: Exhaust Gas Recirculation Control Circuit......................................................................................................................................................................... 169 DTC P0420: Catalyst System Efficiency below Threshold........................................................................................................................................................................ 171 DTC P0443: Evaporative Emission System Purge Control Valve Circuit........................................................................................................................................................... 173 DTC P0462: Fuel Level Sensor “A” Circuit Low................................................................................................................................................................................. 175 DTC P0463: Fuel Level Sensor “A” Circuit High................................................................................................................................................................................ 177 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...................................................................................................................................................................... 179 DTC P0500: Vehicle Speed Sensor “A” Malfunction.............................................................................................................................................................................. 183 DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low................................................................................................................................................................... 185 DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit High.................................................................................................................................................................. 187 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance.................................................................................... 188 DTC P0616: Starter Relay Circuit Low......................................................................................................................................................................................... 189 DTC P0617: Starter Relay Circuit High........................................................................................................................................................................................ 190 DTC P0620: Generator Control Circuit......................................................................................................................................................................................... 192 DTC P0625 / P0626: Generator Field Terminal Circuit Low / High............................................................................................................................................................... 194 DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High........................................................................................................................................................... 196 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................................................................................................. 198 DTC P1603: TCM Trouble Code Detected......................................................................................................................................................................................... 199 DTC P1674: CAN Communication (Bus Off Error)................................................................................................................................................................................. 200 DTC P1675: CAN Communication (Transmission Error)............................................................................................................................................................................ 202 DTC P1676: CAN Communication (Reception Error for TCM)....................................................................................................................................................................... 204 DTC P1678: CAN Communication (Reception Error for BCM)....................................................................................................................................................................... 205 DTC P1685: CAN Communication (Reception Error for ABS Control Module)........................................................................................................................................................ 207 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance....................................................................................................................................................... 208 DTC P2102: Throttle Actuator Control Motor Circuit Low....................................................................................................................................................................... 210 DTC P2103: Throttle Actuator Control Motor Circuit High...................................................................................................................................................................... 211 DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed.................................................................................................................................................... 212 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance....................................................................................................................................................... 213 DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input............................................................................................................................................ 215 DTC P2123: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit High Input........................................................................................................................................... 217 DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input............................................................................................................................................... 220 DTC P2128: Throttle / Pedal Position Sensor / Switch “E” (Sub) Circuit High Input............................................................................................................................................ 222 DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage Correlation................................................................................................................................ 224 DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage Correlation................................................................................................................................ 227 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction........................................................................................................................................................... 229 Inspection of ECM and Its Circuits........................................................................................................................................................................................... 231 ECM Power and Ground Circuit Check........................................................................................................................................................................................... 250 Fuel Injector Circuit Check.................................................................................................................................................................................................. 254 Fuel Pump and Its Circuit Check.............................................................................................................................................................................................. 256 Fuel Pressure Check.......................................................................................................................................................................................................... 259 A/C System Circuits Check.................................................................................................................................................................................................... 261 Electric Load Signal Circuit Check........................................................................................................................................................................................... 265 Radiator Cooling Fan Low Speed Control System Check.......................................................................................................................................................................... 266 Radiator Cooling Fan High Speed Control System Check......................................................................................................................................................................... 268 Repair Instructions.............................................................................................................................................................................................................. 271 Idle Speed and IAC Throttle Valve Opening Inspection......................................................................................................................................................................... 271 Special Tools and Equipment...................................................................................................................................................................................................... 272 Special Tool................................................................................................................................................................................................................. 272 Aux. Emission Control Devices........................................................................................................................................................................................................ 273 Diagnostic Information and Procedures............................................................................................................................................................................................ 273 EGR System Inspection........................................................................................................................................................................................................ 273 Repair Instructions.............................................................................................................................................................................................................. 273 EVAP Canister Purge Inspection............................................................................................................................................................................................... 273 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................................................................................................... 274 Vacuum Passage Inspection.................................................................................................................................................................................................... 275 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................................................................................................... 275 EVAP Canister Purge Valve Inspection......................................................................................................................................................................................... 275 EVAP Canister Inspection..................................................................................................................................................................................................... 276 EGR Valve Removal and Installation........................................................................................................................................................................................... 276 EGR Valve Inspection......................................................................................................................................................................................................... 276 PCV Hose Inspection.......................................................................................................................................................................................................... 276 PCV Valve Inspection......................................................................................................................................................................................................... 277 Special Tools and Equipment...................................................................................................................................................................................................... 277 Special Tool................................................................................................................................................................................................................. 277 Engine Electrical Devices............................................................................................................................................................................................................ 278 Repair Instructions.............................................................................................................................................................................................................. 278 ECM Removal and Installation................................................................................................................................................................................................. 278 MAP Sensor Inspection........................................................................................................................................................................................................ 279 Electric Throttle Body Assembly On-Vehicle Inspection........................................................................................................................................................................ 279 Electric Throttle Body System Calibration.................................................................................................................................................................................... 282 APP Sensor Assembly On-Vehicle Inspection.................................................................................................................................................................................... 282 APP Sensor Assembly Removal and Installation................................................................................................................................................................................. 282 APP Sensor Assembly Inspection............................................................................................................................................................................................... 283 ECT Sensor Removal and Installation.......................................................................................................................................................................................... 283 ECT Sensor Inspection........................................................................................................................................................................................................ 284 HO2S-1 and HO2S-2 Heater On-Vehicle Inspection............................................................................................................................................................................... 284 HO2S-1 and HO2S-2 Removal and Installation................................................................................................................................................................................... 284 CMP Sensor Removal and Installation.......................................................................................................................................................................................... 285 Camshaft Position (CMP) Sensor Inspection.................................................................................................................................................................................... 285 CKP Sensor Removal and Installation.......................................................................................................................................................................................... 286 CKP Sensor Inspection........................................................................................................................................................................................................ 286 Knock Sensor Removal and Installation........................................................................................................................................................................................ 287 Main Relay, Fuel Pump Relay and Starting Motor Control Relay Inspection...................................................................................................................................................... 287 MAF and IAT Sensor On-Vehicle Inspection..................................................................................................................................................................................... 288 MAF and IAT Sensor Removal and Installation.................................................................................................................................................................................. 288 MAF and IAT Sensor Inspection................................................................................................................................................................................................ 289 Electric Load Current Sensor On-Vehicle Inspection........................................................................................................................................................................... 289 Specifications................................................................................................................................................................................................................... 290 Tightening Torque Specifications............................................................................................................................................................................................. 290 Engine Mechanical.................................................................................................................................................................................................................... 291 General Description.............................................................................................................................................................................................................. 291 Engine Construction Description.............................................................................................................................................................................................. 291 Camshaft Position Control (VVT Variable Valve Timing) System Description..................................................................................................................................................... 292 Diagnostic Information and Procedures............................................................................................................................................................................................ 294 Compression Check............................................................................................................................................................................................................ 294 Engine Vacuum Check.......................................................................................................................................................................................................... 295 Valve Lash (Clearance) Inspection............................................................................................................................................................................................ 296 Repair Instructions.............................................................................................................................................................................................................. 299 Air Cleaner Components....................................................................................................................................................................................................... 299 Air Cleaner Element Removal and Installation................................................................................................................................................................................. 299 Air Cleaner Element Inspection and Cleaning.................................................................................................................................................................................. 300 Cylinder Head Cover Removal and Installation................................................................................................................................................................................. 300 Throttle Body and Intake Manifold Components................................................................................................................................................................................. 302 Throttle Body On-Vehicle Inspection.......................................................................................................................................................................................... 303 Electric Throttle Body Assembly Removal and Installation..................................................................................................................................................................... 303 Throttle Body Cleaning....................................................................................................................................................................................................... 304 Intake Manifold Removal and Installation..................................................................................................................................................................................... 304 Engine Mountings Components.................................................................................................................................................................................................. 306 Engine Assembly Removal and Installation..................................................................................................................................................................................... 307 Timing Chain Cover Components................................................................................................................................................................................................ 310 Timing Chain Cover Removal and Installation.................................................................................................................................................................................. 311 Timing Chain Cover Inspection................................................................................................................................................................................................ 313 Oil Control Valve Removal and Installation................................................................................................................................................................................... 313 Oil Control Valve Inspection................................................................................................................................................................................................. 314 Timing Chain and Chain Tensioner Components.................................................................................................................................................................................. 314 Timing Chain and Chain Tensioner Removal and Installation.................................................................................................................................................................... 315 Timing Chain and Chain Tensioner Inspection.................................................................................................................................................................................. 317 Camshaft, Tappet and Shim Components......................................................................................................................................................................................... 318 Camshaft, Tappet and Shim Removal and Installation........................................................................................................................................................................... 319 Camshaft, Tappet and Shim Inspection......................................................................................................................................................................................... 321 Valves and Cylinder Head Components.......................................................................................................................................................................................... 324 Valves and Cylinder Head Removal and Installation............................................................................................................................................................................ 325 Valves and Cylinder Head Disassembly and Assembly............................................................................................................................................................................ 327 Valves and Valve Guides Inspection........................................................................................................................................................................................... 330 Cylinder Head Inspection..................................................................................................................................................................................................... 332 Valve Spring Inspection...................................................................................................................................................................................................... 333 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................................................................................................. 334 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................................................................................................ 335 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................................................................................................ 336 Cylinders, Pistons and Piston Rings Inspection............................................................................................................................................................................... 337 Piston Pins and Connecting Rods Inspection................................................................................................................................................................................... 339 Crank Pin and Connecting Rod Bearings Inspection............................................................................................................................................................................. 340 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................................................................................................... 344 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................................................................................................ 345 Crankshaft Inspection........................................................................................................................................................................................................ 348 Main Bearings Inspection..................................................................................................................................................................................................... 350 Sensor Plate Inspection...................................................................................................................................................................................................... 354 Rear Oil Seal Inspection..................................................................................................................................................................................................... 354 Flywheel Inspection.......................................................................................................................................................................................................... 354 Cylinder Block Inspection.................................................................................................................................................................................................... 354 Specifications................................................................................................................................................................................................................... 355 Tightening Torque Specifications............................................................................................................................................................................................. 355 Special Tools and Equipment...................................................................................................................................................................................................... 357 Recommended Service Material................................................................................................................................................................................................. 357 Special Tool................................................................................................................................................................................................................. 357 Engine Lubrication System............................................................................................................................................................................................................ 359 General Description.............................................................................................................................................................................................................. 359 Engine Lubrication Description............................................................................................................................................................................................... 359 Diagnostic Information and Procedures............................................................................................................................................................................................ 360 Oil Pressure Check........................................................................................................................................................................................................... 360 Repair Instructions.............................................................................................................................................................................................................. 361 Heat Exchanger Components.................................................................................................................................................................................................... 361 Heat Exchanger On-Vehicle Inspection......................................................................................................................................................................................... 362 Heat Exchanger Removal and Installation...................................................................................................................................................................................... 362 Oil Pan and Oil Pump Strainer Components..................................................................................................................................................................................... 363 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................................................................................................... 363 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................................................................................................... 365 Oil Pump Components.......................................................................................................................................................................................................... 366 Oil Pump Removal and Installation............................................................................................................................................................................................ 366 Oil Pump Disassembly and Reassembly.......................................................................................................................................................................................... 366 Oil Pump Inspection.......................................................................................................................................................................................................... 367 Specifications................................................................................................................................................................................................................... 369 Tightening Torque Specifications............................................................................................................................................................................................. 369 Special Tools and Equipment...................................................................................................................................................................................................... 369 Recommended Service Material................................................................................................................................................................................................. 369 Special Tool................................................................................................................................................................................................................. 369 Engine Cooling System................................................................................................................................................................................................................ 370 General Description.............................................................................................................................................................................................................. 370 Cooling System Description................................................................................................................................................................................................... 370 Coolant Description.......................................................................................................................................................................................................... 370 Schematic and Routing Diagram.................................................................................................................................................................................................... 371 Coolant Circulation.......................................................................................................................................................................................................... 371 Diagnostic Information and Procedures............................................................................................................................................................................................ 373 Engine Cooling Symptom Diagnosis............................................................................................................................................................................................. 373 Repair Instructions.............................................................................................................................................................................................................. 374 Cooling System Components.................................................................................................................................................................................................... 374 Coolant Level Check.......................................................................................................................................................................................................... 375 Engine Cooling System Inspection and Cleaning................................................................................................................................................................................ 375 Cooling System Draining...................................................................................................................................................................................................... 375 Cooling System Flush and Refill.............................................................................................................................................................................................. 376 Cooling Water Pipes or Hoses Removal and Installation........................................................................................................................................................................ 377 Thermostat Removal and Installation.......................................................................................................................................................................................... 377 Thermostat Inspection........................................................................................................................................................................................................ 377 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................................................................................................................. 378 Radiator Cooling Fan Relay Inspection........................................................................................................................................................................................ 378 Radiator Cooling Fan Removal and Installation................................................................................................................................................................................ 379 Radiator On-Vehicle Inspection and Cleaning.................................................................................................................................................................................. 379 Radiator Removal and Installation............................................................................................................................................................................................ 379 Water Pump Removal and Installation.......................................................................................................................................................................................... 380 Water Pump Inspection........................................................................................................................................................................................................ 380 Specifications................................................................................................................................................................................................................... 381 Tightening Torque Specifications............................................................................................................................................................................................. 381 Special Tools and Equipment...................................................................................................................................................................................................... 381 Recommended Service Material................................................................................................................................................................................................. 381 Fuel System.......................................................................................................................................................................................................................... 382 Precautions...................................................................................................................................................................................................................... 382 Precautions on Fuel System Service........................................................................................................................................................................................... 382 General Description.............................................................................................................................................................................................................. 382 Fuel System Description...................................................................................................................................................................................................... 382 Fuel Delivery System Description............................................................................................................................................................................................. 382 Fuel Pump Description........................................................................................................................................................................................................ 383 Schematic and Routing Diagram.................................................................................................................................................................................................... 383 Fuel Delivery System Diagram................................................................................................................................................................................................. 383 Diagnostic Information and Procedures............................................................................................................................................................................................ 383 Fuel Pressure Inspection..................................................................................................................................................................................................... 383 Fuel Cut Operation Inspection................................................................................................................................................................................................ 384 Repair Instructions.............................................................................................................................................................................................................. 385 Fuel System Components....................................................................................................................................................................................................... 385 Fuel Hose Disconnecting and Reconnecting..................................................................................................................................................................................... 386 Fuel Pressure Relief Procedure............................................................................................................................................................................................... 388 Fuel Leakage Check Procedure................................................................................................................................................................................................. 388 Fuel Lines On-Vehicle Inspection............................................................................................................................................................................................. 388 Fuel Pipe Removal and Installation........................................................................................................................................................................................... 388 Fuel Injector On-Vehicle Inspection.......................................................................................................................................................................................... 389 Fuel Injector Removal and Installation....................................................................................................................................................................................... 389 Fuel Injector Inspection..................................................................................................................................................................................................... 390 Fuel Filler Cap Inspection................................................................................................................................................................................................... 391 Fuel Tank Inlet Valve Removal and Installation............................................................................................................................................................................... 392 Fuel Tank Inlet Valve Inspection............................................................................................................................................................................................. 393 Fuel Tank Removal and Installation........................................................................................................................................................................................... 393 Fuel Tank Inspection......................................................................................................................................................................................................... 394 Fuel Tank Purging Procedure.................................................................................................................................................................................................. 395 Fuel Pump On-Vehicle Inspection.............................................................................................................................................................................................. 395 Fuel Pump Assembly Removal and Installation.................................................................................................................................................................................. 395 Main Fuel Level Sensor Removal and Installation.............................................................................................................................................................................. 396 Fuel Pump Inspection......................................................................................................................................................................................................... 397 Specifications................................................................................................................................................................................................................... 397 Tightening Torque Specifications............................................................................................................................................................................................. 397 Special Tools and Equipment...................................................................................................................................................................................................... 398 Special Tool................................................................................................................................................................................................................. 398 Ignition System...................................................................................................................................................................................................................... 399 General Description.............................................................................................................................................................................................................. 399 Ignition System Construction................................................................................................................................................................................................. 399 Schematic and Routing Diagram.................................................................................................................................................................................................... 400 Ignition System Wiring Circuit Diagram....................................................................................................................................................................................... 400 Component Location............................................................................................................................................................................................................... 401 Ignition System Components Location.......................................................................................................................................................................................... 401 Diagnostic Information and Procedures............................................................................................................................................................................................ 402 Ignition System Symptom Diagnosis............................................................................................................................................................................................ 402 Reference Waveform of Ignition System........................................................................................................................................................................................ 402 Ignition System Check........................................................................................................................................................................................................ 402 Ignition Spark Test.......................................................................................................................................................................................................... 404 Repair Instructions.............................................................................................................................................................................................................. 404 High-Tension Cord Removal and Installation................................................................................................................................................................................... 404 High-Tension Cord Inspection................................................................................................................................................................................................. 405 Spark Plug Removal and Installation.......................................................................................................................................................................................... 405 Spark Plug Inspection........................................................................................................................................................................................................ 405 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................................................................................................... 406 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................................................................................................ 406 Ignition Timing Inspection................................................................................................................................................................................................... 406 Specifications................................................................................................................................................................................................................... 407 Tightening Torque Specifications............................................................................................................................................................................................. 407 Special Tools and Equipment...................................................................................................................................................................................................... 407 Special Tool................................................................................................................................................................................................................. 407 Starting System...................................................................................................................................................................................................................... 408 Schematic and Routing Diagram.................................................................................................................................................................................................... 408 Cranking System Circuit Diagram.............................................................................................................................................................................................. 408 Diagnostic Information and Procedures............................................................................................................................................................................................ 408 Cranking System Symptom Diagnosis............................................................................................................................................................................................ 408 Cranking System Test......................................................................................................................................................................................................... 410 Repair Instructions.............................................................................................................................................................................................................. 411 Starting Motor Dismounting and Remounting.................................................................................................................................................................................... 411 Starting Motor Components.................................................................................................................................................................................................... 412 Starting Motor Inspection.................................................................................................................................................................................................... 413 Specifications................................................................................................................................................................................................................... 416 Cranking System Specifications............................................................................................................................................................................................... 416 Tightening Torque Specifications............................................................................................................................................................................................. 416 Special Tools and Equipment...................................................................................................................................................................................................... 416 Recommended Service Material................................................................................................................................................................................................. 416 Charging System...................................................................................................................................................................................................................... 417 General Description.............................................................................................................................................................................................................. 417 Battery Description.......................................................................................................................................................................................................... 417 Generator Description........................................................................................................................................................................................................ 418 Diagnostic Information and Procedures............................................................................................................................................................................................ 420 Battery Inspection........................................................................................................................................................................................................... 420 Generator Symptom Diagnosis.................................................................................................................................................................................................. 420 Generator Test (Undercharged Battery Check).................................................................................................................................................................................. 421 Generator Test (Overcharged Battery Check)................................................................................................................................................................................... 422 Repair Instructions.............................................................................................................................................................................................................. 422 Jump Starting in Case of Emergency........................................................................................................................................................................................... 422 Battery Dismounting and Remounting........................................................................................................................................................................................... 423 Water Pump / Generator Drive Belt Tension Inspection and Adjustment.......................................................................................................................................................... 423 Water Pump / Generator Drive Belt Removal and Installation................................................................................................................................................................... 424 Generator Unit Components.................................................................................................................................................................................................... 425 Generator Dismounting and Remounting......................................................................................................................................................................................... 425 Generator Components......................................................................................................................................................................................................... 426 Generator Inspection......................................................................................................................................................................................................... 427 Specifications................................................................................................................................................................................................................... 429 Charging System Specifications............................................................................................................................................................................................... 429 Tightening Torque Specifications............................................................................................................................................................................................. 429 Exhaust System....................................................................................................................................................................................................................... 430 General Description.............................................................................................................................................................................................................. 430 Exhaust System Description................................................................................................................................................................................................... 430 Diagnostic Information and Procedures............................................................................................................................................................................................ 430 Exhaust System Check......................................................................................................................................................................................................... 430 Repair Instructions.............................................................................................................................................................................................................. 431 Exhaust System Components.................................................................................................................................................................................................... 431 Exhaust Manifold Removal and Installation.................................................................................................................................................................................... 432 Exhaust Pipe and Muffler Removal and Installation............................................................................................................................................................................ 434 Specifications................................................................................................................................................................................................................... 434 Tightening Torque Specifications............................................................................................................................................................................................. 434 Suspension............................................................................................................................................................................................................................... 435 Precautions.......................................................................................................................................................................................................................... 437 Precautions...................................................................................................................................................................................................................... 437 Precautions on Suspension.................................................................................................................................................................................................... 437 Suspension General Diagnosis......................................................................................................................................................................................................... 438 Diagnostic Information and Procedures............................................................................................................................................................................................ 438 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................................................................................................... 438 Specifications................................................................................................................................................................................................................... 440 Wheel Alignment Specifications............................................................................................................................................................................................... 440 Front Suspension..................................................................................................................................................................................................................... 442 General Description.............................................................................................................................................................................................................. 442 Front Suspension Construction................................................................................................................................................................................................ 442 Front Wheel Alignment Construction........................................................................................................................................................................................... 443 Repair Instructions.............................................................................................................................................................................................................. 443 Front Wheel Alignment Inspection and Adjustment.............................................................................................................................................................................. 443 Front Strut Assembly Components.............................................................................................................................................................................................. 445 Front Strut Assembly Removal and Installation................................................................................................................................................................................ 445 Front Strut Assembly Disassembly and Assembly................................................................................................................................................................................ 447 Front Strut Assembly Check................................................................................................................................................................................................... 448 Front Wheel Hub and Steering Knuckle Components.............................................................................................................................................................................. 449 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................................................................................................. 449 Front Wheel Hub, Disc, Nut and Bearing Check................................................................................................................................................................................. 453 Suspension Control Arm / Bushing Removal and Installation.................................................................................................................................................................... 453 Suspension Control Arm / Bushing Disassembly and Assembly.................................................................................................................................................................... 454 Suspension Control Arm / Steering Knuckle Check.............................................................................................................................................................................. 455 Suspension Control Arm Bushing Check......................................................................................................................................................................................... 455 Suspension Control Arm Joint Check........................................................................................................................................................................................... 455 Front Suspension Frame, Stabilizer Bar and/or Bushings Components............................................................................................................................................................ 456 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation.............................................................................................................................................. 456 Front Suspension Frame Check................................................................................................................................................................................................. 461 Front Stabilizer Bar, Bushing and/or Joint Check............................................................................................................................................................................. 461 Front Suspension Fasteners Check............................................................................................................................................................................................. 461 Specifications................................................................................................................................................................................................................... 462 Tightening Torque Specifications............................................................................................................................................................................................. 462 Special Tools and Equipment...................................................................................................................................................................................................... 462 Special Tool................................................................................................................................................................................................................. 462 Rear Suspension...................................................................................................................................................................................................................... 464 General Description.............................................................................................................................................................................................................. 464 Rear Suspension Construction................................................................................................................................................................................................. 464 Repair Instructions.............................................................................................................................................................................................................. 465 Rear Shock Absorber Removal and Installation................................................................................................................................................................................. 465 Rear Shock Absorber Inspection............................................................................................................................................................................................... 466 Rear Shock Absorber Bush Removal and Installation............................................................................................................................................................................ 466 Rear Shock Absorber Bush Inspection.......................................................................................................................................................................................... 467 Rear Coil Spring Removal and Installation.................................................................................................................................................................................... 467 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................................................................................................. 468 Spring Upper Seat and Lower Seat Removal and Installation.................................................................................................................................................................... 468 Rear Axle Removal and Installation........................................................................................................................................................................................... 469 Trailing Arm, Rear Axle and Coil Spring Inspection........................................................................................................................................................................... 471 Rear Axle Bush Inspection.................................................................................................................................................................................................... 471 Rear Wheel Hub Components.................................................................................................................................................................................................... 472 Rear Wheel Hub Removal and Installation...................................................................................................................................................................................... 472 Rear Wheel Disc, bolt and Bearing Inspection................................................................................................................................................................................. 473 Spindle Removal and Installation............................................................................................................................................................................................. 474 Spindle Inspection........................................................................................................................................................................................................... 475 Rear Suspension Fasteners Inspection......................................................................................................................................................................................... 475 Specifications................................................................................................................................................................................................................... 475 Tightening Torque Specifications............................................................................................................................................................................................. 475 Special Tools and Equipment...................................................................................................................................................................................................... 475 Special Tool................................................................................................................................................................................................................. 475 Wheels and Tires..................................................................................................................................................................................................................... 476 Precautions...................................................................................................................................................................................................................... 476 Precaution for Emergency Flat Tire Repair Kit................................................................................................................................................................................ 476 General Description.............................................................................................................................................................................................................. 476 Tires Description............................................................................................................................................................................................................ 476 Wheels Description........................................................................................................................................................................................................... 477 Irregular and/or Premature Wear Description.................................................................................................................................................................................. 478 Wear Indicators Description.................................................................................................................................................................................................. 478 Radial Tire Waddle Description............................................................................................................................................................................................... 479 Radial Tire Lead / Pull Description.......................................................................................................................................................................................... 480 Balancing Wheels Description................................................................................................................................................................................................. 480 Repair Instructions.............................................................................................................................................................................................................. 481 General Balance Procedures................................................................................................................................................................................................... 481 Tire Rotation................................................................................................................................................................................................................ 481 Wheel Removal and Installation............................................................................................................................................................................................... 482 Tire Mounting and Dismounting................................................................................................................................................................................................ 483 Tire Repair.................................................................................................................................................................................................................. 483 Tire Repair for Emergency Repaired-Tire with Sealant......................................................................................................................................................................... 483 Specifications................................................................................................................................................................................................................... 484 Wheels and Tires Specifications.............................................................................................................................................................................................. 484 Tightening Torque Specifications............................................................................................................................................................................................. 484 Driveline / Axle......................................................................................................................................................................................................................... 485 Precautions.......................................................................................................................................................................................................................... 486 Precautions...................................................................................................................................................................................................................... 486 Precautions for Driveline / Axle............................................................................................................................................................................................. 486 Drive Shaft / Axle................................................................................................................................................................................................................... 487 General Description.............................................................................................................................................................................................................. 487 Front Drive Shaft Construction............................................................................................................................................................................................... 487 Component Location............................................................................................................................................................................................................... 487 Front Drive Shaft Assembly Components Location............................................................................................................................................................................... 487 Diagnostic Information and Procedures............................................................................................................................................................................................ 488 Front Drive Shaft Symptom Diagnosis.......................................................................................................................................................................................... 488 Repair Instructions.............................................................................................................................................................................................................. 489 Front Drive Shaft Components................................................................................................................................................................................................. 489 Front Drive Shaft Assembly On-Vehicle Inspection............................................................................................................................................................................. 490 Front Drive Shaft Assembly Removal and Installation.......................................................................................................................................................................... 490 Front Drive Shaft Disassembly and Reassembly................................................................................................................................................................................. 492 Center Shaft and Center Bearing Support Disassembly and Reassembly........................................................................................................................................................... 500 Specifications................................................................................................................................................................................................................... 501 Tightening Torque Specifications............................................................................................................................................................................................. 501 Special Tools and Equipment...................................................................................................................................................................................................... 501 Recommended Service Material................................................................................................................................................................................................. 501 Special Tool................................................................................................................................................................................................................. 501 Brakes................................................................................................................................................................................................................................... 503 Precautions.......................................................................................................................................................................................................................... 505 Precautions...................................................................................................................................................................................................................... 505 Precautions for Brakes....................................................................................................................................................................................................... 505 Brake Control System and Diagnosis................................................................................................................................................................................................... 506 Precautions...................................................................................................................................................................................................................... 506 Precautions on Brake......................................................................................................................................................................................................... 506 General Description.............................................................................................................................................................................................................. 506 Brakes Construction.......................................................................................................................................................................................................... 506 Front Brake Hose / Pipe Construction......................................................................................................................................................................................... 507 Rear Brake Hose / Pipe Construction.......................................................................................................................................................................................... 508 Diagnostic Information and Procedures............................................................................................................................................................................................ 508 Brakes Diagnosis Note........................................................................................................................................................................................................ 508 Brakes Symptom Diagnosis..................................................................................................................................................................................................... 509 Repair Instructions.............................................................................................................................................................................................................. 510 Brake Pedal Free Height Inspection........................................................................................................................................................................................... 510 Brake Pedal Play Inspection.................................................................................................................................................................................................. 511 Excessive Pedal Travel Inspection............................................................................................................................................................................................ 511 Master Cylinder and Brake Fluid Level Inspection............................................................................................................................................................................. 511 Stop Light Switch Adjustment................................................................................................................................................................................................. 512 Air Bleeding of Brake System................................................................................................................................................................................................. 512 Front Brake Hose / Pipe Removal and Installation............................................................................................................................................................................. 513 Rear Brake Hose / Pipe Removal and Installation.............................................................................................................................................................................. 513 Brake Hose and Pipe Inspection............................................................................................................................................................................................... 514 Master Cylinder Components................................................................................................................................................................................................... 514 Master Cylinder Assembly Removal and Installation............................................................................................................................................................................ 515 Master Cylinder Reservoir Removal and Installation........................................................................................................................................................................... 516 Master Cylinder Assembly Disassembly and Assembly............................................................................................................................................................................ 517 Master Cylinder Assembly Inspection.......................................................................................................................................................................................... 518 Brake Booster Components..................................................................................................................................................................................................... 518 Booster Operation Inspection................................................................................................................................................................................................. 519 Brake Booster Removal and Installation....................................................................................................................................................................................... 520 Brake Booster Inspection and Adjustment...................................................................................................................................................................................... 521 Specifications................................................................................................................................................................................................................... 521 Tightening Torque Specifications............................................................................................................................................................................................. 521 Special Tools and Equipment...................................................................................................................................................................................................... 521 Recommended Service Material................................................................................................................................................................................................. 521 Front Brakes......................................................................................................................................................................................................................... 522 Repair Instructions.............................................................................................................................................................................................................. 522 Front Disc Brake Components.................................................................................................................................................................................................. 522 Front Disc Brake Pad On-Vehicle Inspection................................................................................................................................................................................... 523 Front Disc Brake Pad Removal and Installation................................................................................................................................................................................ 523 Front Disc Brake Pad Inspection.............................................................................................................................................................................................. 524 Front Disc Brake Caliper Removal and Installation............................................................................................................................................................................ 524 Front Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................ 525 Front Disc Brake Caliper Inspection.......................................................................................................................................................................................... 527 Front Brake Disc Removal and Installation.................................................................................................................................................................................... 527 Front Brake Disc Inspection.................................................................................................................................................................................................. 528 Specifications................................................................................................................................................................................................................... 529 Tightening Torque Specifications............................................................................................................................................................................................. 529 Special Tools and Equipment...................................................................................................................................................................................................... 529 Recommended Service Material................................................................................................................................................................................................. 529 Special Tool................................................................................................................................................................................................................. 529 Rear Brakes.......................................................................................................................................................................................................................... 530 Repair Instructions.............................................................................................................................................................................................................. 530 Rear Disc Brake Components................................................................................................................................................................................................... 530 Rear Disc Brake Pad Removal and Installation................................................................................................................................................................................. 531 Rear Disc Brake Caliper Removal and Installation............................................................................................................................................................................. 532 Rear Disc Brake Pad Inspection............................................................................................................................................................................................... 535 Rear Disc Brake Caliper Disassembly and Assembly............................................................................................................................................................................. 535 Rear Disc Brake Caliper Inspection........................................................................................................................................................................................... 537 Rear Flexible Hose Removal and Installation.................................................................................................................................................................................. 537 Rear Brake Disc Removal and Installation..................................................................................................................................................................................... 538 Rear Brake Disc Inspection................................................................................................................................................................................................... 538 Specifications................................................................................................................................................................................................................... 539 Tightening Torque Specifications............................................................................................................................................................................................. 539 Special Tools and Equipment...................................................................................................................................................................................................... 540 Recommended Service Material................................................................................................................................................................................................. 540 Special Tool................................................................................................................................................................................................................. 540 Parking Brake........................................................................................................................................................................................................................ 541 General Description.............................................................................................................................................................................................................. 541 Parking Brake Cable Construction............................................................................................................................................................................................. 541 Repair Instructions.............................................................................................................................................................................................................. 542 Parking Brake Inspection and Adjustment...................................................................................................................................................................................... 542 Parking Brake Cable Removal and Installation................................................................................................................................................................................. 543 Parking Brake Lever Removal and Installation................................................................................................................................................................................. 543 Specifications................................................................................................................................................................................................................... 544 Tightening Torque Specifications............................................................................................................................................................................................. 544 ABS.................................................................................................................................................................................................................................. 545 Precautions...................................................................................................................................................................................................................... 545 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 545 Precautions in On-Vehicle Service............................................................................................................................................................................................ 545 Precautions in Hydraulic Unit Operation Check................................................................................................................................................................................ 545 General Description.............................................................................................................................................................................................................. 546 ABS Description.............................................................................................................................................................................................................. 546 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................................................................................................... 546 CAN Communication System Description......................................................................................................................................................................................... 547 Schematic and Routing Diagram.................................................................................................................................................................................................... 548 ABS Schematic................................................................................................................................................................................................................ 548 ABS Wiring Circuit Diagram................................................................................................................................................................................................... 549 Component Location............................................................................................................................................................................................................... 551 ABS Components Location...................................................................................................................................................................................................... 551 Front Wheel Speed Sensor Components Location................................................................................................................................................................................. 551 Rear Wheel Speed Sensor Components Location.................................................................................................................................................................................. 552 Diagnostic Information and Procedures............................................................................................................................................................................................ 552 ABS Check.................................................................................................................................................................................................................... 552 ABS Warning Light Check...................................................................................................................................................................................................... 554 EBD Warning Light (Brake Warning Light) Check................................................................................................................................................................................ 554 DTC Check.................................................................................................................................................................................................................... 555 DTC Table.................................................................................................................................................................................................................... 555 DTC Clearance................................................................................................................................................................................................................ 556 Scan Tool Data............................................................................................................................................................................................................... 556 ABS Warning Light Does Not Come ON at Ignition Switch ON..................................................................................................................................................................... 557 ABS Warning Light Comes ON Steady............................................................................................................................................................................................ 558 EBD Warning Light (Brake Warning Light) Comes ON Steady...................................................................................................................................................................... 559 Serial Data Link Circuit Check............................................................................................................................................................................................... 560 DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring.................................................................. 562 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.... 564 DTC C1057: Power Source Circuit.............................................................................................................................................................................................. 565 DTC C1061: ABS Pump Motor and/or Motor Driver Circuit........................................................................................................................................................................ 566 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................................................................................................ 567 DTC C1071: ABS Control Module................................................................................................................................................................................................ 568 DTC U1073: Control Module Communication Bus Off.............................................................................................................................................................................. 569 DTC U1100: Lost Communication with ECM (Reception Error)..................................................................................................................................................................... 571 Repair Instructions.............................................................................................................................................................................................................. 572 ABS Hydraulic Unit Operation Check........................................................................................................................................................................................... 572 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................................................................................................... 573 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................................................................................................... 573 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................................................................................................ 573 Front / Rear Wheel Speed Sensor On-Vehicle Inspection........................................................................................................................................................................ 575 Front Wheel Speed Sensor Removal and Installation............................................................................................................................................................................ 576 Front Wheel Speed Sensor Inspection.......................................................................................................................................................................................... 576 Rear Wheel Speed Sensor Removal and Installation............................................................................................................................................................................. 577 Rear Wheel Speed Sensor Inspection........................................................................................................................................................................................... 578 Front Wheel Encoder On-Vehicle Inspection.................................................................................................................................................................................... 578 Front wheel Encoder Removal and Installation................................................................................................................................................................................. 578 Rear Wheel Encoder On-Vehicle Inspection..................................................................................................................................................................................... 578 Rear Wheel Encoder Removal and Installation.................................................................................................................................................................................. 578 Specifications................................................................................................................................................................................................................... 579 Tightening Torque Specifications............................................................................................................................................................................................. 579 Special Tools and Equipment...................................................................................................................................................................................................... 579 Special Tool................................................................................................................................................................................................................. 579 Transmission / Transaxle................................................................................................................................................................................................................. 581 Precautions.......................................................................................................................................................................................................................... 584 Precautions...................................................................................................................................................................................................................... 584 Precautions on Transmission / Transaxle...................................................................................................................................................................................... 584 Automatic Transmission/Transaxle..................................................................................................................................................................................................... 585 Precautions...................................................................................................................................................................................................................... 585 Precautions in Diagnosing Trouble............................................................................................................................................................................................ 585 Precautions for Disassembly and Reassembly................................................................................................................................................................................... 585 General Description.............................................................................................................................................................................................................. 587 A/T Description.............................................................................................................................................................................................................. 587 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................................................................................................. 590 Table of Component Operation................................................................................................................................................................................................. 591 Brake Interlock System Construction.......................................................................................................................................................................................... 592 A/T Diagnosis General Description............................................................................................................................................................................................ 592 On-Board Diagnostic System Description....................................................................................................................................................................................... 592 CAN Communication System Description......................................................................................................................................................................................... 593 Schematic and Routing Diagram.................................................................................................................................................................................................... 594 Transmission Control Module (TCM) Wiring Diagram............................................................................................................................................................................. 594 Automatic Gear Shift Table................................................................................................................................................................................................... 596 Component Location............................................................................................................................................................................................................... 597 Electronic Shift Control System Components Location.......................................................................................................................................................................... 597 Diagnostic Information and Procedures............................................................................................................................................................................................ 599 A/T System Check............................................................................................................................................................................................................. 599 Visual Inspection............................................................................................................................................................................................................ 602 Malfunction Indicator Lamp (MIL) Check....................................................................................................................................................................................... 602 Transmission Warning Light Check............................................................................................................................................................................................. 602 DTC Table.................................................................................................................................................................................................................... 603 DTC Check.................................................................................................................................................................................................................... 604 DTC Clearance................................................................................................................................................................................................................ 604 Fail-Safe Table.............................................................................................................................................................................................................. 605 Scan Tool Data............................................................................................................................................................................................................... 607 A/T Basic Check.............................................................................................................................................................................................................. 610 Road Test.................................................................................................................................................................................................................... 611 Manual Road Test............................................................................................................................................................................................................. 613 Engine Brake Test............................................................................................................................................................................................................ 614 Stall Test................................................................................................................................................................................................................... 614 Time Lag Test................................................................................................................................................................................................................ 615 Line Pressure Test........................................................................................................................................................................................................... 616 “P” Range Test............................................................................................................................................................................................................... 617 A/T Symptom Diagnosis........................................................................................................................................................................................................ 618 No Gear Shift to 4th gear.................................................................................................................................................................................................... 626 No Lock-Up Occurs............................................................................................................................................................................................................ 627 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON.................................................................................................................................... 628 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON.......................................................................................................................................... 628 DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL input)....................................................................................................................................................... 629 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................................................................................................. 631 DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low............................................................................................................................................................. 633 DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High............................................................................................................................................................ 634 DTC P0717: Input / Turbine Speed Sensor “A” Circuit Malfunction.............................................................................................................................................................. 635 DTC P0722: Output Speed Sensor Circuit No Signal............................................................................................................................................................................. 637 DTC P0787: Shift / Timing Solenoid Low....................................................................................................................................................................................... 638 DTC P0788: Shift / Timing Solenoid High...................................................................................................................................................................................... 640 DTC P0962: Pressure Control Solenoid “A” Control Circuit Low................................................................................................................................................................. 642 DTC P0963: Pressure Control Solenoid “A” Control Circuit High................................................................................................................................................................ 644 DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low........................................................................................................................... 646 DTC P0974 / P0977: Shift Solenoid “A” / Shift Solenoid “B” Control Circuit High.............................................................................................................................................. 648 DTC P1702: Internal Control Module Memory Check Sum Error.................................................................................................................................................................... 650 DTC P1703: Can Invalid Data - TCM............................................................................................................................................................................................ 650 DTC P1723: Range Select Switch Malfunction................................................................................................................................................................................... 651 DTC P1774: CAN Communication Bus Off......................................................................................................................................................................................... 653 DTC P1775: High Speed CAN Communication Bus Off (Transmission Error)......................................................................................................................................................... 655 DTC P1777: TCM Lost Communication with ECM (Reception Error)................................................................................................................................................................. 657 DTC P1778: TCM Lost Communication with BCM (Reception Error)................................................................................................................................................................. 658 DTC P1878: Torque Converter Clutch Shudder................................................................................................................................................................................... 659 DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High............................................................................................................................................ 660 DTC P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit Low..................................................................................................................................... 662 Inspection of TCM and Its Circuits........................................................................................................................................................................................... 664 TCM Power and Ground Circuit Check........................................................................................................................................................................................... 668 Brake Interlock System Inspection............................................................................................................................................................................................ 669 Repair Instructions.............................................................................................................................................................................................................. 670 Learning Control Initialization.............................................................................................................................................................................................. 670 A/T Fluid Level Check........................................................................................................................................................................................................ 671 A/T Fluid Change............................................................................................................................................................................................................. 672 Select Lever Components...................................................................................................................................................................................................... 672 Select Lever Assembly Removal and Installation............................................................................................................................................................................... 672 Select Lever Knob Installation............................................................................................................................................................................................... 672 Select Lever Inspection...................................................................................................................................................................................................... 673 “3” Position Switch Inspection............................................................................................................................................................................................... 673 Shift Lock Solenoid Inspection............................................................................................................................................................................................... 673 Shift Lock Solenoid Replacement.............................................................................................................................................................................................. 673 Select Cable Components...................................................................................................................................................................................................... 674 Select Cable Removal and Installation........................................................................................................................................................................................ 674 Select Cable Adjustment...................................................................................................................................................................................................... 675 Key Interlock Cable Removal and Installation................................................................................................................................................................................. 675 Transmission Range Sensor (Shift Switch) Inspection and Adjustment........................................................................................................................................................... 677 Output Shaft Speed Sensor Removal and Installation........................................................................................................................................................................... 678 Output Shaft Speed Sensor Inspection......................................................................................................................................................................................... 678 Input Shaft Speed Sensor Removal and Installation............................................................................................................................................................................ 678 Input Shaft Speed Sensor Inspection.......................................................................................................................................................................................... 679 Transmission Fluid Temperature Sensor Removal and Installation............................................................................................................................................................... 679 Transmission Fluid Temperature Sensor Inspection............................................................................................................................................................................. 680 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation................................................................................................................................... 680 Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection................................................................................................................................................ 681 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...................................................................................................... 683 Pressure Control Solenoid Valve Inspection................................................................................................................................................................................... 683 Transmission Control Module (TCM) Removal and Installation................................................................................................................................................................... 684 A/T Relay Inspection......................................................................................................................................................................................................... 685 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 685 A/T Fluid Cooler Hoses Replacement........................................................................................................................................................................................... 686 Automatic Transaxle Unit Components.......................................................................................................................................................................................... 687 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................................................................................................... 688 Automatic Transaxle Assembly Components...................................................................................................................................................................................... 690 Automatic Transaxle Unit Disassembly......................................................................................................................................................................................... 692 Oil Pump Assembly Components................................................................................................................................................................................................. 703 Oil Pump Assembly Disassembly and Reassembly................................................................................................................................................................................. 704 Oil Pump Assembly Inspection................................................................................................................................................................................................. 704 Direct Clutch Assembly Components............................................................................................................................................................................................ 706 Direct Clutch Assembly Preliminary Check..................................................................................................................................................................................... 706 Direct Clutch Assembly Disassembly and Reassembly............................................................................................................................................................................ 707 Direct Clutch Assembly Inspection............................................................................................................................................................................................ 709 Forward and Reverse Clutch Assembly Components............................................................................................................................................................................... 710 Forward and Reverse Clutch Assembly Preliminary Check........................................................................................................................................................................ 711 Forward and Reverse Clutch Assembly Disassembly and Reassembly............................................................................................................................................................... 711 Forward and Reverse Clutch Assembly Inspection............................................................................................................................................................................... 715 2nd Brake Piston Assembly Components......................................................................................................................................................................................... 716 2nd Brake Piston Assembly Disassembly and Reassembly......................................................................................................................................................................... 716 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components.................................................................................................................................................... 717 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly.................................................................................................................................... 718 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection.................................................................................................................................................... 719 Countershaft Assembly Components............................................................................................................................................................................................. 720 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 720 Valve Body Assembly Components............................................................................................................................................................................................... 721 Valve Body Assembly Disassembly and Reassembly............................................................................................................................................................................... 722 Differential Assembly Components............................................................................................................................................................................................. 723 Differential Assembly Disassembly and Reassembly............................................................................................................................................................................. 724 Differential Assembly Inspection............................................................................................................................................................................................. 725 Torque Converter Housing Disassembly and Reassembly.......................................................................................................................................................................... 726 Transaxle Case Disassembly and Reassembly.................................................................................................................................................................................... 728 Automatic Transaxle Unit Inspection and Adjustment........................................................................................................................................................................... 729 Automatic Transaxle Unit Assembly............................................................................................................................................................................................ 732 Specifications................................................................................................................................................................................................................... 749 Tightening Torque Specifications............................................................................................................................................................................................. 749 Special Tools and Equipment...................................................................................................................................................................................................... 750 Recommended Service Material................................................................................................................................................................................................. 750 Special Tool................................................................................................................................................................................................................. 750 Manual Transmission/Transaxle........................................................................................................................................................................................................ 753 General Description.............................................................................................................................................................................................................. 753 Manual Transaxle Construction and Servicing.................................................................................................................................................................................. 753 Diagnostic Information and Procedures............................................................................................................................................................................................ 755 Manual Transaxle Symptom Diagnosis........................................................................................................................................................................................... 755 Repair Instructions.............................................................................................................................................................................................................. 755 Manual Transaxle Oil Change.................................................................................................................................................................................................. 755 Differential Side Oil Seal Replacement....................................................................................................................................................................................... 756 Gear Shift Control Lever and Cable Components................................................................................................................................................................................ 757 Gear Shift Control Lever and Cable Removal and Installation.................................................................................................................................................................. 758 Gear Select Control Cable Adjustment......................................................................................................................................................................................... 758 Back Up Light Switch Removal and Installation................................................................................................................................................................................ 759 Back Up Light Switch Inspection.............................................................................................................................................................................................. 759 Manual Transaxle Unit Components............................................................................................................................................................................................. 760 Manual Transaxle Unit Dismounting and Remounting............................................................................................................................................................................. 761 Gear Shift and Select Shaft Assembly Components.............................................................................................................................................................................. 763 Gear Shift and Select Shaft Assembly Removal and Installation................................................................................................................................................................ 763 Gear Shift and Select Shaft Disassembly and Assembly......................................................................................................................................................................... 764 Manual Transaxle Assembly Components......................................................................................................................................................................................... 765 Fifth Gear Disassembly and Assembly.......................................................................................................................................................................................... 766 Manual Transaxle Assembly Disassembly and Reassembly......................................................................................................................................................................... 768 Transaxle Right Case Disassembly and Assembly................................................................................................................................................................................ 775 Transaxle Left Case Disassembly and Assembly................................................................................................................................................................................. 776 Input Shaft and Countershaft Components...................................................................................................................................................................................... 777 Input Shaft Assembly Disassembly and Reassembly.............................................................................................................................................................................. 778 Countershaft Assembly Disassembly and Reassembly............................................................................................................................................................................. 780 Synchronizer Parts Inspection................................................................................................................................................................................................ 783 Gear Shift Shaft Components.................................................................................................................................................................................................. 783 5th and Reverse Gear Shift Shafts Disassembly and Assembly................................................................................................................................................................... 784 Gear Shift Shaft and Fork Inspection......................................................................................................................................................................................... 784 Differential Components...................................................................................................................................................................................................... 785 Differential Disassembly and Assembly........................................................................................................................................................................................ 785 Specifications................................................................................................................................................................................................................... 787 Tightening Torque Specifications............................................................................................................................................................................................. 787 Special Tools and Equipment...................................................................................................................................................................................................... 788 Recommended Service Material................................................................................................................................................................................................. 788 Special Tool................................................................................................................................................................................................................. 788 Clutch............................................................................................................................................................................................................................... 791 General Description.............................................................................................................................................................................................................. 791 Clutch Construction.......................................................................................................................................................................................................... 791 Diagnostic Information and Procedures............................................................................................................................................................................................ 792 Clutch System Symptom Diagnosis.............................................................................................................................................................................................. 792 Repair Instructions.............................................................................................................................................................................................................. 792 Clutch Pedal Inspection...................................................................................................................................................................................................... 792 Clutch Fluid Level Inspection................................................................................................................................................................................................ 793 Air Bleeding of Clutch System................................................................................................................................................................................................ 793 Clutch Pedal Position (CPP) Switch Removal and Installation.................................................................................................................................................................. 794 Clutch Pedal Position (CPP) Switch Inspection and Adjustment................................................................................................................................................................. 795 Clutch Fluid Pipe and Hose Components........................................................................................................................................................................................ 795 Clutch Fluid Pipe Removal and Installation................................................................................................................................................................................... 796 Clutch Fluid Pipe Inspection................................................................................................................................................................................................. 796 Clutch Master Cylinder Removal and Installation.............................................................................................................................................................................. 796 Clutch Operating Cylinder Removal and Installation........................................................................................................................................................................... 797 Clutch Operating Cylinder Inspection......................................................................................................................................................................................... 797 Clutch Pedal and Clutch Pedal Bracket Components............................................................................................................................................................................. 797 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................................................................................................ 798 Clutch Cover, Clutch Disc and Flywheel Removal and Installation.............................................................................................................................................................. 798 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................................................................................................ 800 Clutch Release System Removal and Installation............................................................................................................................................................................... 801 Clutch Release System Inspection............................................................................................................................................................................................. 803 Specifications................................................................................................................................................................................................................... 803 Tightening Torque Specifications............................................................................................................................................................................................. 803 Special Tools and Equipment...................................................................................................................................................................................................... 804 Recommended Service Material................................................................................................................................................................................................. 804 Special Tool................................................................................................................................................................................................................. 804 Steering................................................................................................................................................................................................................................. 805 Precautions.......................................................................................................................................................................................................................... 807 Precautions...................................................................................................................................................................................................................... 807 Precautions on Steering...................................................................................................................................................................................................... 807 Steering General Diagnosis........................................................................................................................................................................................................... 808 Precautions...................................................................................................................................................................................................................... 808 Precautions for Steering Diagnosis........................................................................................................................................................................................... 808 Diagnostic Information and Procedures............................................................................................................................................................................................ 809 Steering Symptom Diagnosis................................................................................................................................................................................................... 809 Steering Wheel and Column............................................................................................................................................................................................................ 810 Precautions...................................................................................................................................................................................................................... 810 Service Precautions of Steering Wheel and Column............................................................................................................................................................................. 810 General Description.............................................................................................................................................................................................................. 810 Steering Wheel and Column Construction....................................................................................................................................................................................... 810 Diagnostic Information and Procedures............................................................................................................................................................................................ 811 Checking Steering Column for Accident Damage................................................................................................................................................................................. 811 Repair Instructions.............................................................................................................................................................................................................. 812 Steering Wheel and Column Construction....................................................................................................................................................................................... 812 Steering Wheel Removal and Installation...................................................................................................................................................................................... 813 Contact Coil Cable Assembly Removal and Installation......................................................................................................................................................................... 814 Centering Contact Coil Cable Assembly........................................................................................................................................................................................ 815 Contact Coil Cable Assembly Inspection....................................................................................................................................................................................... 815 Steering Column Removal and Installation..................................................................................................................................................................................... 815 Steering Column Inspection................................................................................................................................................................................................... 817 Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)........................................................................................................................................ 817 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................................................................................................ 818 Steering Lower Shaft Removal and Installation................................................................................................................................................................................ 818 Specifications................................................................................................................................................................................................................... 819 Tightening Torque Specifications............................................................................................................................................................................................. 819 Special Tools and Equipment...................................................................................................................................................................................................... 819 Special Tool................................................................................................................................................................................................................. 819 Power Assisted Steering System....................................................................................................................................................................................................... 820 Precautions...................................................................................................................................................................................................................... 820 Steering System Note......................................................................................................................................................................................................... 820 Precautions in Diagnosing Troubles........................................................................................................................................................................................... 820 General Description.............................................................................................................................................................................................................. 821 P/S System Description....................................................................................................................................................................................................... 821 EPS Diagnosis General Description............................................................................................................................................................................................ 822 On-Board Diagnostic System Description....................................................................................................................................................................................... 822 Schematic and Routing Diagram.................................................................................................................................................................................................... 823 EPS System Wiring Circuit Diagram............................................................................................................................................................................................ 823 Diagnostic Information and Procedures............................................................................................................................................................................................ 824 EPS System Check............................................................................................................................................................................................................. 824 “EPS” Warning Light Check.................................................................................................................................................................................................... 827 DTC Check.................................................................................................................................................................................................................... 828 DTC Clearance................................................................................................................................................................................................................ 828 DTC Table.................................................................................................................................................................................................................... 829 Scan Tool Data............................................................................................................................................................................................................... 831 Visual Inspection............................................................................................................................................................................................................ 832 P/S System Symptom Diagnosis................................................................................................................................................................................................. 832 Serial Data Link Circuit Check............................................................................................................................................................................................... 833 “EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts..................................................................................................................................... 834 “EPS” Warning Light Remains ON Steady after Engine Starts.................................................................................................................................................................... 835 DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation......................................................................................................................................................... 836 DTC C1114: Steering Torque Sensor Reference Power Supply Circuit............................................................................................................................................................. 838 DTC C1117: Steering Torque Sensor Failure Signal Circuit Low................................................................................................................................................................. 840 DTC C1118: Steering Torque Sensor Failure Signal Circuit High................................................................................................................................................................ 841 DTC C1119: Steering Torque Sensor Power Supply Circuit....................................................................................................................................................................... 843 DTC C1121 / C1123 / C1124: VSS Circuit Failure............................................................................................................................................................................... 845 DTC C1122: Engine Speed Signal............................................................................................................................................................................................... 847 DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure................................................................................................................................................................. 849 DTC C1153: P/S Control Module Power Supply Circuit Voltage Low............................................................................................................................................................... 851 DTC C1155: P/S Control Module Failure........................................................................................................................................................................................ 852 P/S Control Module Power Supply and Ground Circuit Check..................................................................................................................................................................... 853 Inspection of P/S Control Module and Its Circuits............................................................................................................................................................................ 854 Steering Wheel Play Check.................................................................................................................................................................................................... 858 Steering Force Check......................................................................................................................................................................................................... 858 Repair Instructions.............................................................................................................................................................................................................. 859 Steering Gear Case Assembly Components....................................................................................................................................................................................... 859 Tie-Rod End Boot On-Vehicle Inspection....................................................................................................................................................................................... 860 Tie-Rod End Removal and Installation......................................................................................................................................................................................... 860 Tie-Rod End Inspection....................................................................................................................................................................................................... 861 Steering Shaft Joint On-Vehicle Inspection................................................................................................................................................................................... 861 Steering Gear Case Assembly Removal and Installation......................................................................................................................................................................... 861 Steering Rack Boot Inspection................................................................................................................................................................................................ 862 Tie-Rod / Rack Boot Removal and Installation................................................................................................................................................................................. 862 Steering Rack Plunger Removal and Installation............................................................................................................................................................................... 864 Steering Rack Plunger Inspection............................................................................................................................................................................................. 864 P/S Control Module Removal and Installation.................................................................................................................................................................................. 865 Torque Sensor and Its Circuit Inspection..................................................................................................................................................................................... 865 P/S Motor and Its Circuit Inspection......................................................................................................................................................................................... 866 Specifications................................................................................................................................................................................................................... 867 Tightening Torque Specifications............................................................................................................................................................................................. 867 Special Tools and Equipment...................................................................................................................................................................................................... 868 Recommended Service Material................................................................................................................................................................................................. 868 Special Tool................................................................................................................................................................................................................. 868 HVAC..................................................................................................................................................................................................................................... 869 Precautions.......................................................................................................................................................................................................................... 872 Precautions...................................................................................................................................................................................................................... 872 Precautions on HVAC.......................................................................................................................................................................................................... 872 Heater and Ventilation............................................................................................................................................................................................................... 873 General Description.............................................................................................................................................................................................................. 873 Heater and Ventilation Construction.......................................................................................................................................................................................... 873 Schematic and Routing Diagram.................................................................................................................................................................................................... 874 Heater and Ventilation Wiring Circuit Diagram................................................................................................................................................................................ 874 Diagnostic Information and Procedures............................................................................................................................................................................................ 875 Heater and Ventilation Symptom Diagnosis..................................................................................................................................................................................... 875 Repair Instructions.............................................................................................................................................................................................................. 876 HVAC Unit Components......................................................................................................................................................................................................... 876 HVAC Unit Removal and Installation........................................................................................................................................................................................... 876 Blower Motor Removal and Installation........................................................................................................................................................................................ 876 Blower Motor Inspection...................................................................................................................................................................................................... 876 Blower Motor Resistor Removal and Installation............................................................................................................................................................................... 877 Blower Motor Resistor Inspection............................................................................................................................................................................................. 877 Blower Motor Relay Inspection................................................................................................................................................................................................ 878 HVAC Control Unit Components................................................................................................................................................................................................. 878 HVAC Control Unit Removal and Installation................................................................................................................................................................................... 879 Blower Speed Selector Inspection............................................................................................................................................................................................. 881 Air Intake Selector Inspection............................................................................................................................................................................................... 881 Air Intake Control Actuator Removal and Installation......................................................................................................................................................................... 881 Air Intake Control Actuator Inspection....................................................................................................................................................................................... 882 Center Ventilation Louver Removal and Installation........................................................................................................................................................................... 882 Side Ventilation Louver Removal and Installation............................................................................................................................................................................. 883 HVAC Air Filter Removal and Installation (If Equipped)....................................................................................................................................................................... 884 HVAC Air Filter Inspection (If Equipped)..................................................................................................................................................................................... 884 Air Conditioning System.............................................................................................................................................................................................................. 885 Manual Type...................................................................................................................................................................................................................... 885 Precautions.................................................................................................................................................................................................................. 885 A/C System Caution....................................................................................................................................................................................................... 885 Precautions on Servicing A/C System...................................................................................................................................................................................... 886 General Description.......................................................................................................................................................................................................... 887 Refrigerant Type Identification.......................................................................................................................................................................................... 887 Compressor Type Identification........................................................................................................................................................................................... 887 Sub-Cool A/C System Description.......................................................................................................................................................................................... 888 A/C Operation Description................................................................................................................................................................................................ 888 Schematic and Routing Diagram................................................................................................................................................................................................ 889 Major Components of A/C System........................................................................................................................................................................................... 889 A/C System Wiring Diagram................................................................................................................................................................................................ 890 Diagnostic Information and Procedures........................................................................................................................................................................................ 891 A/C System Symptom Diagnosis............................................................................................................................................................................................. 891 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 893 A/C System Performance Inspection........................................................................................................................................................................................ 895 A/C System Inspection at ECM............................................................................................................................................................................................. 900 Repair Instructions.......................................................................................................................................................................................................... 901 Operation Procedure for Refrigerant Charge............................................................................................................................................................................... 901 Condenser Assembly On-Vehicle Inspection................................................................................................................................................................................. 906 Condenser Assembly Removal and Installation.............................................................................................................................................................................. 906 Desiccant Removal and Installation....................................................................................................................................................................................... 907 HVAC Unit Components..................................................................................................................................................................................................... 908 HVAC Unit Removal and Installation....................................................................................................................................................................................... 909 Evaporator Inspection.................................................................................................................................................................................................... 909 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation........................................................................................................................................... 910 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection......................................................................................................................................................... 910 Expansion Valve Removal and Installation................................................................................................................................................................................. 911 Expansion Valve Inspection............................................................................................................................................................................................... 911 A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................................................................................................................................... 911 A/C Refrigerant Pressure Sensor Removal and Installation................................................................................................................................................................. 911 A/C Switch Inspection.................................................................................................................................................................................................... 912 Compressor Relay Inspection.............................................................................................................................................................................................. 912 Compressor Drive Belt Inspection and Adjustment.......................................................................................................................................................................... 912 Compressor Drive Belt Removal and Installation........................................................................................................................................................................... 913 Compressor Assembly Removal and Installation............................................................................................................................................................................. 913 Compressor Assembly Components for MITSUBISHI Make Compressor............................................................................................................................................................ 915 Compressor Assembly Components for MATSUSHITADENKI Make Compressor....................................................................................................................................................... 916 Magnet Clutch Inspection for MITSUBISHI Make Compressor.................................................................................................................................................................. 916 Magnet Clutch Inspection for MATSUSHITADENKI Make Compressor............................................................................................................................................................. 916 Magnet Clutch Removal and Installation for MITSUBISHI Make Compressor.................................................................................................................................................... 917 Magnet Clutch Removal and Installation for MATSUSHITADENKI Make Compressor............................................................................................................................................... 918 Thermal Switch Inspection for MITSUBISHI Make Compressor................................................................................................................................................................. 920 Thermal Switch Removal and Installation for MITSUBISHI Make Compressor................................................................................................................................................... 920 Relief Valve Inspection for MITSUBISHI Make Compressor................................................................................................................................................................... 921 Relief Valve Inspection for MATSUSHITADENKI Make Compressor.............................................................................................................................................................. 921 Relief Valve Removal and Installation for MITSUBISHI Make Compressor..................................................................................................................................................... 921 Relief Valve Removal and Installation for MATSUSHITADENKI Make Compressor................................................................................................................................................ 922 Specifications............................................................................................................................................................................................................... 922 Tightening Torque Specifications......................................................................................................................................................................................... 922 Special Tools and Equipment.................................................................................................................................................................................................. 923 Recommended Service Material............................................................................................................................................................................................. 923 Special Tool............................................................................................................................................................................................................. 923 Automatic Type................................................................................................................................................................................................................... 924 Precautions.................................................................................................................................................................................................................. 924 A/C System Caution....................................................................................................................................................................................................... 924 Precautions in Diagnosing Trouble........................................................................................................................................................................................ 924 Precautions on Servicing A/C System...................................................................................................................................................................................... 924 General Description.......................................................................................................................................................................................................... 924 Auto A/C System Description.............................................................................................................................................................................................. 924 HVAC Control Module Operation Description................................................................................................................................................................................ 926 Refrigerant Type Identification.......................................................................................................................................................................................... 926 Compressor Type Identification........................................................................................................................................................................................... 926 Sub-Cool A/C System Description.......................................................................................................................................................................................... 926 A/C Operation Description................................................................................................................................................................................................ 926 On-Board Diagnostic System Description................................................................................................................................................................................... 927 Schematic and Routing Diagram................................................................................................................................................................................................ 927 Major Components of A/C System........................................................................................................................................................................................... 927 A/C System Wiring Diagram................................................................................................................................................................................................ 928 Diagnostic Information and Procedures........................................................................................................................................................................................ 929 A/C System Symptom Diagnosis............................................................................................................................................................................................. 929 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................................................................................................... 933 DTC Check................................................................................................................................................................................................................ 933 DTC Clearance............................................................................................................................................................................................................ 934 DTC Table................................................................................................................................................................................................................ 935 Fail-Safe Table.......................................................................................................................................................................................................... 936 Scan Tool Data........................................................................................................................................................................................................... 937 Air Conditioning System Check............................................................................................................................................................................................ 938 Visual Inspection........................................................................................................................................................................................................ 940 DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction.................................................................................................................................................. 940 DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction.......................................................................................................................................... 941 DTC B1504: Sunload Sensor and/or Its Circuit Malfunction................................................................................................................................................................. 943 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction................................................................................................................................. 944 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................................................................................................... 946 DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction................................................................................................................................................... 948 DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction...................................................................................................................................................... 951 DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction.......................................................................................................................................................... 953 DTC B1546: A/C Refrigerant Pressure Malfunction.......................................................................................................................................................................... 954 DTC B1551: Serial Communication Circuit Malfunction...................................................................................................................................................................... 955 DTC B1552: Serial Communication Signal Malfunction....................................................................................................................................................................... 956 DTC B1553: CAN Communication Signal Malfunction.......................................................................................................................................................................... 956 DTC B1557: Vehicle Speed Sensor Signal Malfunction....................................................................................................................................................................... 957 DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction.......................................................................................................................................................... 957 DTC B1562: Outside Air Temperature Sensor Signal Malfunction............................................................................................................................................................. 957 DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction............................................................................................................................................................ 958 Inspection of HVAC Control Module and Its Circuit........................................................................................................................................................................ 958 A/C System Performance Inspection........................................................................................................................................................................................ 961 A/C System Inspection at ECM............................................................................................................................................................................................. 961 Repair Instructions.......................................................................................................................................................................................................... 962 Operation Procedure for Refrigerant Charge............................................................................................................................................................................... 962 HVAC Unit Components..................................................................................................................................................................................................... 963 HVAC Unit Removal and Installation....................................................................................................................................................................................... 964 Temperature Control Actuator Removal and Installation.................................................................................................................................................................... 964 Temperature Control Actuator Inspection.................................................................................................................................................................................. 964 Air Flow Control Actuator Removal and Installation....................................................................................................................................................................... 965 Air Flow Control Actuator Inspection..................................................................................................................................................................................... 965 Air Intake Control Actuator Removal and Installation..................................................................................................................................................................... 966 Air Intake Control Actuator Inspection................................................................................................................................................................................... 966 Actuator Linkage Inspection.............................................................................................................................................................................................. 966 Blower Motor Controller Removal and Installation......................................................................................................................................................................... 966 Blower Motor Controller Inspection....................................................................................................................................................................................... 967 HVAC Control Module Removal and Installation............................................................................................................................................................................. 967 Sunload Sensor Removal and Installation.................................................................................................................................................................................. 968 Sunload Sensor Inspection................................................................................................................................................................................................ 968 Outside Air Temperature Sensor Removal and Installation.................................................................................................................................................................. 968 Outside Air Temperature Sensor Inspection................................................................................................................................................................................ 968 Inside Air Temperature Sensor Removal and Installation................................................................................................................................................................... 968 Inside Air Temperature Sensor Inspection................................................................................................................................................................................. 968 Condenser Assembly On-Vehicle Inspection................................................................................................................................................................................. 969 Condenser Assembly Removal and Installation.............................................................................................................................................................................. 969 Desiccant Removal and Installation....................................................................................................................................................................................... 969 Evaporator Inspection.................................................................................................................................................................................................... 969 Evaporator Temperature Sensor Removal and Installation................................................................................................................................................................... 969 Evaporator Temperature Sensor Inspection................................................................................................................................................................................. 969 Expansion Valve Removal and Installation................................................................................................................................................................................. 969 Expansion Valve Inspection............................................................................................................................................................................................... 969 A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................................................................................................................................... 969 A/C Refrigerant Pressure Sensor Removal and Installation................................................................................................................................................................. 969 Compressor Relay Inspection.............................................................................................................................................................................................. 969 Compressor Drive Belt Inspection and Adjustment.......................................................................................................................................................................... 969 Compressor Drive Belt Removal and Installation........................................................................................................................................................................... 969 Compressor Assembly Removal and Installation............................................................................................................................................................................. 969 Compressor Assembly Components........................................................................................................................................................................................... 969 Magnet Clutch Removal and Installation................................................................................................................................................................................... 969 Magnet Clutch Inspection................................................................................................................................................................................................. 969 Thermal Switch Inspection................................................................................................................................................................................................ 969 Thermal Switch Removal and Installation.................................................................................................................................................................................. 969 Relief Valve Inspection.................................................................................................................................................................................................. 969 Special Tools and Equipment.................................................................................................................................................................................................. 970 Special Tool............................................................................................................................................................................................................. 970 Restraint................................................................................................................................................................................................................................ 971 Precautions.......................................................................................................................................................................................................................... 973 Precautions...................................................................................................................................................................................................................... 973 Precautions on Restraint..................................................................................................................................................................................................... 973 Seat Belts........................................................................................................................................................................................................................... 974 Precautions...................................................................................................................................................................................................................... 974 Precautions on Service and Diagnosis of Seat Belt............................................................................................................................................................................ 974 General Description.............................................................................................................................................................................................................. 974 Seat Belt Construction....................................................................................................................................................................................................... 974 Diagnostic Information and Procedures............................................................................................................................................................................................ 975 Repair and Inspection Required after Accident................................................................................................................................................................................ 975 Repair Instructions.............................................................................................................................................................................................................. 976 Front Seat Belt Components................................................................................................................................................................................................... 976 Front Seat Belt Removal and Installation..................................................................................................................................................................................... 977 Front Seat Belt Inspection................................................................................................................................................................................................... 977 Rear Seat Belt Components.................................................................................................................................................................................................... 979 Rear Seat Belt Removal and Installation...................................................................................................................................................................................... 980 Rear Seat Belt Inspection.................................................................................................................................................................................................... 980 Specifications................................................................................................................................................................................................................... 980 Tightening Torque Specifications............................................................................................................................................................................................. 980 Air Bag System....................................................................................................................................................................................................................... 981 Precautions...................................................................................................................................................................................................................... 981 Precautions on Service and Diagnosis of Air Bag System....................................................................................................................................................................... 981 Precautions on Handling and Storage of Air Bag System Components............................................................................................................................................................. 982 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................................................................................................ 985 General Description.............................................................................................................................................................................................................. 985 Air Bag System Construction.................................................................................................................................................................................................. 985 Air Bag System Input / Output Table.......................................................................................................................................................................................... 986 Schematic and Routing Diagram.................................................................................................................................................................................................... 987 Air Bag System Wiring Circuit Diagram........................................................................................................................................................................................ 987 Component Location............................................................................................................................................................................................................... 989 Air Bag System Components, Wiring and Connectors Location.................................................................................................................................................................... 989 Diagnostic Information and Procedures............................................................................................................................................................................................ 990 Air Bag Diagnostic System Check.............................................................................................................................................................................................. 990 Air Bag Diagnostic System Check Flow......................................................................................................................................................................................... 990 DTC Table.................................................................................................................................................................................................................... 991 DTC Check.................................................................................................................................................................................................................... 992 DTC Clearance................................................................................................................................................................................................................ 992 “AIR BAG” Warning Right Comes ON Steady...................................................................................................................................................................................... 994 “AIR BAG” Warning Right Does Not Come ON..................................................................................................................................................................................... 996 “AIR BAG” Warning Right Flashes.............................................................................................................................................................................................. 997 DTC B1013: SDM fault......................................................................................................................................................................................................... 998 DTC B1014: “AIR BAG” Warning Right Circuit Failure........................................................................................................................................................................... 998 DTC B1016: Power Source Voltage High......................................................................................................................................................................................... 999 DTC B1017: Power Source Voltage Low..........................................................................................................................................................................................1001 DTC B1021: Front Air Bag Module Deployed.....................................................................................................................................................................................1003 DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed................................................................................................................................................................1003 DTC B1026: Pretensioner Activated............................................................................................................................................................................................1004 DTC B1027: Reusable Number Exceeded..........................................................................................................................................................................................1005 DTC B1031: Driver Air Bag Initiator Circuit Resistance High..................................................................................................................................................................1005 DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...................................................................................................................................................................1010 DTC B1033: Driver Air Bag Initiator Circuit Short to Ground..................................................................................................................................................................1015 DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...........................................................................................................................................................1020 DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...............................................................................................................................................................1025 DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low................................................................................................................................................................1028 DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...............................................................................................................................................................1031 DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit........................................................................................................................................................1034 DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High.........................................................................................................................................1037 DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low..........................................................................................................................................1039 DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground.........................................................................................................................................1041 DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit..................................................................................................................................1043 DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High.........................................................................................................................................1045 DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low..........................................................................................................................................1048 DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground.........................................................................................................................................1051 DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit..................................................................................................................................1054 DTC B1071: Forward-Sensor Performance Problem................................................................................................................................................................................1057 DTC B1072: Forward-Sensor Communication Error................................................................................................................................................................................1057 DTC B1073: Forward-Sensor Circuit Short to Ground............................................................................................................................................................................1057 DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open.............................................................................................................................................................1059 DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem........................................................................................................................................................1061 DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error........................................................................................................................................................1061 DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground....................................................................................................................................................1061 DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open.....................................................................................................................................1062 DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID............................................................................................................................................................1064 DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High.................................................................................................................................1065 DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low..................................................................................................................................1067 DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground.................................................................................................................................1069 DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit..........................................................................................................................1071 Contact Coil Cable and Its Circuit Check.....................................................................................................................................................................................1074 Inspection of Intermittent and Poor Connections..............................................................................................................................................................................1076 Repair and Inspection Required after Accident................................................................................................................................................................................1077 Repair Instructions..............................................................................................................................................................................................................1079 Disabling Air Bag System.....................................................................................................................................................................................................1079 Enabling Air Bag System......................................................................................................................................................................................................1080 SDM Removal and Installation.................................................................................................................................................................................................1081 SDM Inspection...............................................................................................................................................................................................................1082 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................................................................................................1082 Driver Air Bag (Inflator) Module Inspection..................................................................................................................................................................................1084 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................................................................................................1084 Passenger Air Bag (Inflator) Module Inspection...............................................................................................................................................................................1086 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................................................................................................1086 Side-Air Bag (Inflator) Inspection...........................................................................................................................................................................................1088 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................................................................................................1088 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................................................................................................1090 Forward-Sensor Removal and Installation......................................................................................................................................................................................1090 Forward-Sensor Inspection....................................................................................................................................................................................................1091 Side-Sensor Removal and Installation.........................................................................................................................................................................................1092 Side-Sensor Inspection.......................................................................................................................................................................................................1093 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................................................................................................1093 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................................................................................................1094 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................................................................................................1105 Specifications...................................................................................................................................................................................................................1106 Tightening Torque Specifications.............................................................................................................................................................................................1106 Special Tools and Equipment......................................................................................................................................................................................................1106 Use of Special Tools.........................................................................................................................................................................................................1106 Recommended Service Material.................................................................................................................................................................................................1108 Special Tool.................................................................................................................................................................................................................1108 Body, Cab and Accessories................................................................................................................................................................................................................1111 Precautions..........................................................................................................................................................................................................................1115 Precautions......................................................................................................................................................................................................................1115 Precautions on Body, Cab and Accessories.....................................................................................................................................................................................1115 Precautions for Body Service.................................................................................................................................................................................................1115 Fastener Caution for Body Service............................................................................................................................................................................................1115 Wiring Systems.......................................................................................................................................................................................................................1116 Precautions......................................................................................................................................................................................................................1116 Cautions in Body Electrical System Servicing.................................................................................................................................................................................1116 General Description..............................................................................................................................................................................................................1116 Abbreviations................................................................................................................................................................................................................1116 Wire / Connector Color Symbols...............................................................................................................................................................................................1116 Symbols and Marks............................................................................................................................................................................................................1117 How to Read Connector Layout Diagram.........................................................................................................................................................................................1119 How to Read Connector Codes and Terminal Nos.................................................................................................................................................................................1120 How to Read Ground Point.....................................................................................................................................................................................................1122 How to Read Power Supply Diagram.............................................................................................................................................................................................1123 How to Read System Circuit Diagram...........................................................................................................................................................................................1124 Connector Layout Diagram.........................................................................................................................................................................................................1126 Connector Layout Diagram.....................................................................................................................................................................................................1126 Engine Compartment...........................................................................................................................................................................................................1126 Instrument Panel.............................................................................................................................................................................................................1132 Door, Roof...................................................................................................................................................................................................................1136 Floor........................................................................................................................................................................................................................1140 Rear.........................................................................................................................................................................................................................1146 Ground Point.....................................................................................................................................................................................................................1147 Ground (earth) Point.........................................................................................................................................................................................................1147 Power Supply Diagram.............................................................................................................................................................................................................1148 Power Supply Diagram.........................................................................................................................................................................................................1148 Fuses and the Protected Parts................................................................................................................................................................................................1150 Fuses in Main Fuse Box (RHD).................................................................................................................................................................................................1150 Fuses in Main Fuse Box (LHD).................................................................................................................................................................................................1150 Individual Circuit Fuse Box No. 1............................................................................................................................................................................................1151 Individual Circuit Fuse Box No. 2 (In J/B)...................................................................................................................................................................................1152 Junction Block (J/B) Connector / Fuse Layout.................................................................................................................................................................................1154 Junction Block Inner Circuit (Overview)......................................................................................................................................................................................1155 Junction Block Inner Circuit (Detail)........................................................................................................................................................................................1157 System Circuit Diagram...........................................................................................................................................................................................................1162 System Circuit Diagram.......................................................................................................................................................................................................1162 A-1 Cranking System Circuit Diagram..........................................................................................................................................................................................1163 A-2 Charging System Circuit Diagram..........................................................................................................................................................................................1164 A-3 Ignition System Circuit Diagram..........................................................................................................................................................................................1165 A-4 Cooling System Circuit Diagram...........................................................................................................................................................................................1166 A-5 Engine and A/C Control System Circuit Diagram............................................................................................................................................................................1167 A-6 A/T Control System Circuit Diagram.......................................................................................................................................................................................1172 A-7 Immobilizer System Circuit Diagram.......................................................................................................................................................................................1174 A-8 Body Control System Circuit Diagram......................................................................................................................................................................................1175 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................................................................................................1179 B-2 Rear Wiper and Washer Circuit Diagram....................................................................................................................................................................................1180 B-3 Rear Defogger Circuit Diagram............................................................................................................................................................................................1181 B-4 Power Window Circuit Diagram.............................................................................................................................................................................................1182 B-5 Power Door Lock Circuit Diagram..........................................................................................................................................................................................1184 B-6 Power Mirror Circuit Diagram.............................................................................................................................................................................................1186 B-7 Horn Circuit Diagram.....................................................................................................................................................................................................1187 B-8 Seat Heater Circuit Diagram..............................................................................................................................................................................................1188 B-9 Keyless Start System Circuit Diagram.....................................................................................................................................................................................1189 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................................................................................................1190 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................................................................................................1191 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................................................................................................1192 D-1 Headlight System Circuit Diagram.........................................................................................................................................................................................1194 D-2 Position, Tail and Licence Plate Light System Circuit Diagram............................................................................................................................................................1196 D-3 Front Fog Light System Circuit Diagram...................................................................................................................................................................................1197 D-4 Illumination Light System Circuit Diagram................................................................................................................................................................................1198 D-5 Interior Light System Circuit Diagram....................................................................................................................................................................................1199 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram..............................................................................................................................................................1200 D-7 Brake Light System Circuit Diagram.......................................................................................................................................................................................1202 D-8 Back-Up Light System Circuit Diagram.....................................................................................................................................................................................1203 D-9 Headlight Beam Leveling System Circuit Diagram...........................................................................................................................................................................1204 D-10 Rear Fog Light Circuit Diagram..........................................................................................................................................................................................1205 E-1 Heater System Circuit Diagram............................................................................................................................................................................................1206 E-2 Auto A/C System Circuit Diagram..........................................................................................................................................................................................1208 F-1 Air-Bag System Circuit Diagram...........................................................................................................................................................................................1210 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................................................................................................1212 F-3 Power Steering System Circuit Diagram....................................................................................................................................................................................1214 G-1 Audio System Circuit Diagram.............................................................................................................................................................................................1216 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................................................................................................1217 List of Connector................................................................................................................................................................................................................1218 List of Connectors...........................................................................................................................................................................................................1218 C Connector..................................................................................................................................................................................................................1218 D Connector (M16A engine)....................................................................................................................................................................................................1219 E Connector..................................................................................................................................................................................................................1219 G Connector..................................................................................................................................................................................................................1221 J Connector..................................................................................................................................................................................................................1223 K Connector..................................................................................................................................................................................................................1224 L Connector..................................................................................................................................................................................................................1224 M Connector (SPORT model)....................................................................................................................................................................................................1226 O Connector..................................................................................................................................................................................................................1226 R Connector..................................................................................................................................................................................................................1226 Lighting Systems.....................................................................................................................................................................................................................1227 Component Location...............................................................................................................................................................................................................1227 Lighting System Components Location..........................................................................................................................................................................................1227 Interior Light System Location...............................................................................................................................................................................................1228 Diagnostic Information and Procedures............................................................................................................................................................................................1228 Headlight Symptom Diagnosis..................................................................................................................................................................................................1228 Headlight Leveling System Symptom Diagnosis (If Equipped)....................................................................................................................................................................1228 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................................................................................................1229 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................................................................................................1229 Back-Up Light Symptom Diagnosis..............................................................................................................................................................................................1230 Brake Light Symptom Diagnosis................................................................................................................................................................................................1230 Front Fog Light Symptom Diagnosis (If Equipped)..............................................................................................................................................................................1230 Interior Light Symptom Diagnosis.............................................................................................................................................................................................1231 Repair Instructions..............................................................................................................................................................................................................1231 Headlight Housing Removal and Installation...................................................................................................................................................................................1231 Headlight Bulb Replacement...................................................................................................................................................................................................1232 Headlight Aiming Adjustment with Screen......................................................................................................................................................................................1232 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................................................................................................1234 Headlight Switch (in Lighting Switch) Inspection.............................................................................................................................................................................1234 Hazard Warning Switch Removal and Installation...............................................................................................................................................................................1234 Hazard Warning Switch Inspection.............................................................................................................................................................................................1235 Brake Light Switch Inspection................................................................................................................................................................................................1235 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................................................................................................1235 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................................................................................................1235 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................................................................................................1235 Turn Signal and Hazard Warning Relay Inspection..............................................................................................................................................................................1236 License Light Removal and Installation.......................................................................................................................................................................................1236 Front Fog Light Removal and Installation (If Equipped).......................................................................................................................................................................1237 Front Fog Light Bulb Replacement (If Equipped)...............................................................................................................................................................................1237 Front Fog Light Switch Inspection (If Equipped)..............................................................................................................................................................................1237 Front Fog Light Relay Inspection (If Equipped)...............................................................................................................................................................................1237 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................................................................................................1238 Headlight Leveling Switch Inspection (If Equipped)...........................................................................................................................................................................1239 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................................................................................................1239 Instrumentation / Driver Info. / Horn................................................................................................................................................................................................1240 Precautions......................................................................................................................................................................................................................1240 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................................................................................................1240 General Description..............................................................................................................................................................................................................1240 CAN Communication System Description.........................................................................................................................................................................................1240 Auto Volume Control System Description (If Equipped).........................................................................................................................................................................1241 Schematic and Routing Diagram....................................................................................................................................................................................................1242 Combination Meter Circuit Diagram............................................................................................................................................................................................1242 Component Location...............................................................................................................................................................................................................1244 Audio System Component Location..............................................................................................................................................................................................1244 Diagnostic Information and Procedures............................................................................................................................................................................................1244 Speedometer and VSS Symptom Diagnosis........................................................................................................................................................................................1244 Tachometer Symptom Diagnosis.................................................................................................................................................................................................1244 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................................................................................................1245 Fuel Meter Symptom Diagnosis.................................................................................................................................................................................................1245 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................................................................................................1245 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................................................................................................1246 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................................................................................................1246 Seat Belt Reminder Light Symptom Diagnosis (If Equipped).....................................................................................................................................................................1246 A/T Shift Position Indicator Symptom Diagnosis (A/T Model)...................................................................................................................................................................1247 Charge Warning Light Symptom Diagnosis.......................................................................................................................................................................................1247 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................................................................................................1247 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................................................................................................1248 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................................................................................................1248 Horn Symptom Diagnosis.......................................................................................................................................................................................................1248 Information Display Symptom Diagnosis (If Equipped)..........................................................................................................................................................................1249 Clock Symptom Diagnosis (If Equipped)........................................................................................................................................................................................1250 Audio System Symptom Diagnosis (If Equipped).................................................................................................................................................................................1250 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................................................................................................1251 Navigation Symptom Diagnosis (If Equipped)...................................................................................................................................................................................1252 Repair Instructions..............................................................................................................................................................................................................1252 Ignition Switch Removal and Installation.....................................................................................................................................................................................1252 Ignition Switch Inspection...................................................................................................................................................................................................1252 Combination Meter Removal and Installation...................................................................................................................................................................................1253 Fuel Level Sensor Removal and Installation...................................................................................................................................................................................1253 Fuel Level Sensor Inspection.................................................................................................................................................................................................1253 Oil Pressure Switch Removal and Installation.................................................................................................................................................................................1253 Oil Pressure Switch Inspection...............................................................................................................................................................................................1254 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................................................................................................1254 Brake Fluid Level Switch Inspection..........................................................................................................................................................................................1254 Parking Brake Switch Inspection..............................................................................................................................................................................................1254 Door Switch (Front / Rear Door) Inspection...................................................................................................................................................................................1255 Rear End Door Switch Inspection..............................................................................................................................................................................................1255 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................................................................................................1255 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................................................................................................1255 Instrument Panel Removal and Installation....................................................................................................................................................................................1256 Information Display (Clock) Removal and Installation.........................................................................................................................................................................1257 Audio Unit Removal and Installation..........................................................................................................................................................................................1257 Front Speaker Removal and Installation.......................................................................................................................................................................................1257 Rear Speaker Removal and Installation........................................................................................................................................................................................1258 Horn Removal and Installation................................................................................................................................................................................................1258 Horn Inspection..............................................................................................................................................................................................................1258 Horn Relay Inspection........................................................................................................................................................................................................1258 Antenna Amplifier Removal and Installation...................................................................................................................................................................................1259 Remote Audio Control Switch Inspection (If Equipped).........................................................................................................................................................................1259 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...............................................................................................................................................................1259 Specifications...................................................................................................................................................................................................................1259 Tightening Torque Specifications.............................................................................................................................................................................................1259 Wipers / Washers.....................................................................................................................................................................................................................1260 Diagnostic Information and Procedures............................................................................................................................................................................................1260 Front Wiper and Washer Symptom Diagnosis.....................................................................................................................................................................................1260 Rear Wiper and Washer Symptom Diagnosis......................................................................................................................................................................................1260 Repair Instructions..............................................................................................................................................................................................................1261 Wipers and Washers Components................................................................................................................................................................................................1261 Washer Tank and Washer Pump Removal and Installation.........................................................................................................................................................................1262 Washer Pump Inspection.......................................................................................................................................................................................................1262 Windshield Wiper Removal and Installation....................................................................................................................................................................................1263 Windshield Wiper Motor Inspection............................................................................................................................................................................................1264 Rear Wiper Removal and Installation..........................................................................................................................................................................................1265 Rear Wiper Motor Inspection..................................................................................................................................................................................................1266 Windshield Wiper and Washer Switch Removal and Installation..................................................................................................................................................................1266 Windshield Wiper and Washer Switch Inspection................................................................................................................................................................................1267 Rear Wiper and Washer Switch Removal and Installation........................................................................................................................................................................1268 Rear Wiper and Washer Switch Inspection......................................................................................................................................................................................1268 Rear Wiper Relay Removal and Installation....................................................................................................................................................................................1269 Rear Wiper Relay Inspection..................................................................................................................................................................................................1269 Specifications...................................................................................................................................................................................................................1269 Tightening Torque Specifications.............................................................................................................................................................................................1269 Glass / Windows / Mirrors............................................................................................................................................................................................................1270 General Description..............................................................................................................................................................................................................1270 Rear End Door Window Defogger System Description.............................................................................................................................................................................1270 Windshield Construction......................................................................................................................................................................................................1270 Diagnostic Information and Procedures............................................................................................................................................................................................1271 Rear End door Window Defogger Symptom Diagnosis..............................................................................................................................................................................1271 Power Window Control System Symptom Diagnosis................................................................................................................................................................................1271 Power Door Mirror Control System Symptom Diagnosis...........................................................................................................................................................................1272 Door Mirror Heater Symptom Diagnosis (If Equipped)...........................................................................................................................................................................1272 Repair Instructions..............................................................................................................................................................................................................1273 Windshield Removal and Installation..........................................................................................................................................................................................1273 Front Door Window Components.................................................................................................................................................................................................1277 Front Door Glass Removal and Installation....................................................................................................................................................................................1277 Front Door Window Regulator Removal and Installation.........................................................................................................................................................................1278 Front Door Window Regulator Inspection.......................................................................................................................................................................................1279 Rear Door Window Components..................................................................................................................................................................................................1279 Rear Door Glass Removal and Installation.....................................................................................................................................................................................1280 Rear Door Window Regulator Removal and Installation..........................................................................................................................................................................1281 Rear Door Window Regulator Inspection........................................................................................................................................................................................1281 Rear End Door Window Components..............................................................................................................................................................................................1282 Rear End Door Glass Removal and Installation.................................................................................................................................................................................1282 Rear End Door Window Defogger Switch Inspection..............................................................................................................................................................................1283 Rear End Door Window Defogger Relay Inspection...............................................................................................................................................................................1283 Rear End Door Window Defogger Wire Inspection................................................................................................................................................................................1284 Rear End Door Window Defogger Wire Repair....................................................................................................................................................................................1284 Power Window Main Switch Inspection..........................................................................................................................................................................................1285 Power Window Sub Switch Inspection...........................................................................................................................................................................................1286 Door Mirror Components.......................................................................................................................................................................................................1287 Door Mirror Removal and Installation.........................................................................................................................................................................................1287 Power Door Mirror Switch Inspection..........................................................................................................................................................................................1287 Power Door Mirror Actuator Inspection........................................................................................................................................................................................1288 Door Mirror Heater Switch Inspection (If Equipped)...........................................................................................................................................................................1288 Door Mirror Heater Inspection (If Equipped)..................................................................................................................................................................................1288 Special Tools and Equipment......................................................................................................................................................................................................1288 Recommended Service Material.................................................................................................................................................................................................1288 Security and Locks...................................................................................................................................................................................................................1289 General Description..............................................................................................................................................................................................................1289 Key Coding Construction......................................................................................................................................................................................................1289 Rear End Door Opener System Description......................................................................................................................................................................................1289 Component Location...............................................................................................................................................................................................................1290 Power Door Lock and Keyless Entry System Component Location..................................................................................................................................................................1290 Diagnostic Information and Procedures............................................................................................................................................................................................1291 Power Door Lock System Symptom Diagnosis.....................................................................................................................................................................................1291 Power Door Lock System Operation Inspection..................................................................................................................................................................................1291 Keyless Entry System Symptom Diagnosis (If Equipped).........................................................................................................................................................................1292 Keyless Entry System Operation Inspection....................................................................................................................................................................................1293 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................................................................................................1293 Rear End Door Opener System Symptom Diagnosis................................................................................................................................................................................1293 Rear End Door Opener System Operation Inspection.............................................................................................................................................................................1293 Repair Instructions..............................................................................................................................................................................................................1294 Front Door Lock Assembly Components..........................................................................................................................................................................................1294 Front Door Lock Assembly Removal and Installation............................................................................................................................................................................1294 Front Door Lock Assembly Inspection..........................................................................................................................................................................................1296 Power Door Lock Switch Inspection............................................................................................................................................................................................1296 Door Key Cylinder Switch Inspection..........................................................................................................................................................................................1296 Power Door Lock Actuator Inspection..........................................................................................................................................................................................1297 Rear Door Lock Assembly Components...........................................................................................................................................................................................1298 Rear Door Lock Assembly Removal and Installation.............................................................................................................................................................................1298 Rear Door Lock Assembly Inspection...........................................................................................................................................................................................1298 Rear End Door Lock Assembly Components.......................................................................................................................................................................................1299 Rear End Door Lock Assembly Removal and Installation.........................................................................................................................................................................1299 Rear End Door Lock Assembly Inspection.......................................................................................................................................................................................1300 Rear End Door Opener Switch Inspection.......................................................................................................................................................................................1300 Replacement of Transmitter Battery...........................................................................................................................................................................................1301 Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System).................................................................................................................................1301 Keyless Entry Answer Back Function Change- over Procedure (If Equipped)......................................................................................................................................................1302 Keyless Entry Receiver Removal and Installation..............................................................................................................................................................................1302 Keyless Entry Receiver and Its Circuit Inspection............................................................................................................................................................................1303 Specifications...................................................................................................................................................................................................................1304 Tightening Torque Specifications.............................................................................................................................................................................................1304 Special Tools and Equipment......................................................................................................................................................................................................1304 Recommended Service Material.................................................................................................................................................................................................1304 Seats................................................................................................................................................................................................................................1305 Repair Instructions..............................................................................................................................................................................................................1305 Front Seat Components........................................................................................................................................................................................................1305 Front Seat Removal and Installation..........................................................................................................................................................................................1306 Rear Seat Components.........................................................................................................................................................................................................1307 Rear Seat Removal and Installation...........................................................................................................................................................................................1307 Specifications...................................................................................................................................................................................................................1308 Tightening Torque Specifications.............................................................................................................................................................................................1308 Special Tools and Equipment......................................................................................................................................................................................................1308 Recommended Service Material.................................................................................................................................................................................................1308 Interior Trim........................................................................................................................................................................................................................1309 Repair Instructions..............................................................................................................................................................................................................1309 Floor Carpet Removal and Installation........................................................................................................................................................................................1309 Head Lining Removal and Installation.........................................................................................................................................................................................1309 Console Box Components.......................................................................................................................................................................................................1310 Specifications...................................................................................................................................................................................................................1311 Tightening Torque Specifications.............................................................................................................................................................................................1311 Hood / Fenders / Doors...............................................................................................................................................................................................................1312 Repair Instructions..............................................................................................................................................................................................................1312 Hood Removal and Installation................................................................................................................................................................................................1312 Hood Inspection and Adjustment...............................................................................................................................................................................................1312 Front Fender Components......................................................................................................................................................................................................1313 Front Fender Removal and Installation........................................................................................................................................................................................1313 Front Door Assembly Components...............................................................................................................................................................................................1314 Front Door Assembly Removal and Installation.................................................................................................................................................................................1314 Rear Door Assembly Components................................................................................................................................................................................................1316 Rear Door Assembly Removal and Installation..................................................................................................................................................................................1316 Rear End Door Assembly Components............................................................................................................................................................................................1317 Rear End Door Assembly Removal and Installation..............................................................................................................................................................................1318 Specifications...................................................................................................................................................................................................................1320 Tightening Torque Specifications.............................................................................................................................................................................................1320 Special Tools and Equipment......................................................................................................................................................................................................1320 Recommended Service Material.................................................................................................................................................................................................1320 Body Structure.......................................................................................................................................................................................................................1321 Repair Instructions..............................................................................................................................................................................................................1321 Front Bumper and Rear Bumper Components......................................................................................................................................................................................1321 Cowl Top Components..........................................................................................................................................................................................................1322 Specifications...................................................................................................................................................................................................................1323 Body Dimensions..............................................................................................................................................................................................................1323 Panel Clearance..............................................................................................................................................................................................................1330 Paint / Coatings.....................................................................................................................................................................................................................1331 General Description..............................................................................................................................................................................................................1331 Anti-Corrosion Treatment Construction........................................................................................................................................................................................1331 Plastic Parts Finishing......................................................................................................................................................................................................1332 Component Location...............................................................................................................................................................................................................1333 Sealant Application Areas....................................................................................................................................................................................................1333 Under Coating Application Areas..............................................................................................................................................................................................1338 Anti-Corrosion Compound Application Area.....................................................................................................................................................................................1340 Exterior Trim........................................................................................................................................................................................................................1341 Repair Instructions..............................................................................................................................................................................................................1341 Roof Molding Components......................................................................................................................................................................................................1341 Splash Guard (If Equipped) Components........................................................................................................................................................................................1342 Control Systems..........................................................................................................................................................................................................................1343 Precautions..........................................................................................................................................................................................................................1345 Precautions......................................................................................................................................................................................................................1345 Precautions for Control Systems..............................................................................................................................................................................................1345 Body Electrical Control System.......................................................................................................................................................................................................1346 Precautions......................................................................................................................................................................................................................1346 Precautions in Diagnosing Trouble............................................................................................................................................................................................1346 General Description..............................................................................................................................................................................................................1346 BCM General Description......................................................................................................................................................................................................1346 CAN Communication System Description.........................................................................................................................................................................................1347 Theft Deterrent Light........................................................................................................................................................................................................1348 Security Alarm Description (If Equipped).....................................................................................................................................................................................1348 Schematic and Routing Diagram....................................................................................................................................................................................................1350 Body Electrical Control System Wiring Circuit Diagram........................................................................................................................................................................1350 Connector Layout Diagram of BCM and Junction Block Assembly..................................................................................................................................................................1352 Component Location...............................................................................................................................................................................................................1353 BCM and Related System Component Location....................................................................................................................................................................................1353 Diagnostic Information and Procedures............................................................................................................................................................................................1354 BCM Self-Diagnosis Function..................................................................................................................................................................................................1354 Body Electrical Control System Check.........................................................................................................................................................................................1356 Scan Tool Data...............................................................................................................................................................................................................1358 DTC Table....................................................................................................................................................................................................................1360 DTC Check....................................................................................................................................................................................................................1360 DTC Clearance................................................................................................................................................................................................................1361 BCM Power Circuit and Ground Circuit Check...................................................................................................................................................................................1362 DTC B1133 (DTC No. 1133): Battery Voltage Too High...........................................................................................................................................................................1363 DTC B1141 / DTC B1142 / DTC B1143 (No. 1141 / No. 1142/ No. 1143): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction........................................................................................1364 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................................................................................................1365 DTC B1157 (No. 1157): Air Bag Deployment Signal Input........................................................................................................................................................................1366 DTC B1170 (No. 1170): EEPROM Access Error....................................................................................................................................................................................1367 DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error)......................................................................................................................................................1367 DTC U1073 (No. 1073): Control Module Communication Bus Off...................................................................................................................................................................1369 DTC U1100 (No. 1100): Lost Communication with ECM............................................................................................................................................................................1370 DTC U1101 (No. 1101): Lost Communication with TCM............................................................................................................................................................................1372 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................................................................................................1373 Inspection of BCM and its Circuits...........................................................................................................................................................................................1375 Repair Instructions..............................................................................................................................................................................................................1383 BCM (Included in Junction Block Assembly) Removal and Installation...........................................................................................................................................................1383 Outside Air Temperature Sensor Removal and Installation......................................................................................................................................................................1384 Outside Air Temperature Sensor Inspection....................................................................................................................................................................................1384 Security Alarm Mode Selection Procedure (If Equipped)........................................................................................................................................................................1384 Special Tools and Equipment......................................................................................................................................................................................................1384 Special Tool.................................................................................................................................................................................................................1384 Immobilizer Control System...........................................................................................................................................................................................................1385 Precautions......................................................................................................................................................................................................................1385 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1385 Precaution in Replacing ECM..................................................................................................................................................................................................1385 Precautions in Handling Immobilizer Control System...........................................................................................................................................................................1385 General Description..............................................................................................................................................................................................................1386 Immobilizer Control System Introduction......................................................................................................................................................................................1386 Immobilizer Control System Components Location...............................................................................................................................................................................1387 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................................................................................................1387 Schematic and Routing Diagram....................................................................................................................................................................................................1388 Immobilizer Control System Wiring Circuit Diagram............................................................................................................................................................................1388 Diagnostic Information and Procedures............................................................................................................................................................................................1389 Immobilizer Control System Check.............................................................................................................................................................................................1389 Diagnostic Trouble Code (DTC) Check..........................................................................................................................................................................................1389 Diagnostic Trouble Code (DTC) Clearance......................................................................................................................................................................................1390 Diagnostic Trouble Code (DTC) Table..........................................................................................................................................................................................1390 Scan Tool Data...............................................................................................................................................................................................................1391 Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................................................................................................1391 Immobilizer Indicator Lamp Remains ON after Engine Starts....................................................................................................................................................................1392 DTC P1614: Transponder Response Error........................................................................................................................................................................................1393 DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only).....................................................................................................................................1393 DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only).................................................................................................................................1395 DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)......................................................................................1395 DTC P1621: Immobilizer Communication Line Error..............................................................................................................................................................................1396 DTC P1622: EEPROM Reading / Writing Error....................................................................................................................................................................................1397 DTC P1623: Unregistered Transponder..........................................................................................................................................................................................1397 DTC P1625: Immobilizer Antenna Error.........................................................................................................................................................................................1398 DTC P1636: Immobilizer Information Registration Failure......................................................................................................................................................................1399 DTC P1638: Immobilizer Information Mismatched................................................................................................................................................................................1400 Inspection of Immobilizer Control Module (ICM) and Its Circuit...............................................................................................................................................................1401 Repair Instructions..............................................................................................................................................................................................................1402 Immobilizer Control Module (ICM) Removal and Installation....................................................................................................................................................................1402 Registration of the Ignition Key.............................................................................................................................................................................................1403 Procedure after ECM Replacement..............................................................................................................................................................................................1403 Special Tools and Equipment......................................................................................................................................................................................................1403 Special Tool.................................................................................................................................................................................................................1403 Keyless Start System.................................................................................................................................................................................................................1404 General Description..............................................................................................................................................................................................................1404 Keyless Start System Description.............................................................................................................................................................................................1404 Parts and Functions..........................................................................................................................................................................................................1405 Keyless Engine Start Function................................................................................................................................................................................................1406 Door Lock Function of Keyless Start System...................................................................................................................................................................................1407 Operation Area of Remote Controller..........................................................................................................................................................................................1408 Alarm Function...............................................................................................................................................................................................................1409 CAN Communication System Description.........................................................................................................................................................................................1409 Schematic and Routing Diagram....................................................................................................................................................................................................1410 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................................................................................................1410 Diagnostic Information and Procedures............................................................................................................................................................................................1411 Precautions in Diagnosing Troubles...........................................................................................................................................................................................1411 Self-Diagnosis Function......................................................................................................................................................................................................1411 Keyless Start System Diagnosis Introduction..................................................................................................................................................................................1411 Keyless Start System Check...................................................................................................................................................................................................1411 Customer Questionnaire (Example).............................................................................................................................................................................................1412 Key Indicator Lamp Check.....................................................................................................................................................................................................1413 DTC Check....................................................................................................................................................................................................................1413 DTC Table....................................................................................................................................................................................................................1414 DTC Clearance................................................................................................................................................................................................................1415 Keyless Start System Symptom Diagnosis.......................................................................................................................................................................................1416 Keyless Start System Operation Inspection....................................................................................................................................................................................1417 Door Lock Operation (Keyless Start System)...................................................................................................................................................................................1417 Inspection of Keyless Start Control Module and Its Circuits..................................................................................................................................................................1418 No DTC Detection After Performing DTC Check..................................................................................................................................................................................1422 Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.).....................................................................................................................1423 Keyless Start Control Module Power and Ground Circuit Check..................................................................................................................................................................1425 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................................................................................................1426 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................................................................................................1427 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)..........................................................................................................1427 DTC No. 31: Lost Communication with BCM......................................................................................................................................................................................1428 DTC No. 33: Control Module Communication Bus Off.............................................................................................................................................................................1430 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure............................................................................................................................1431 Repair Instructions..............................................................................................................................................................................................................1433 Antennas and Request Switches Removal and Installation.......................................................................................................................................................................1433 Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection..............................................................................................................................................1434 Steering Lock Unit Removal and Installation..................................................................................................................................................................................1434 Steering Lock Unit Inspection................................................................................................................................................................................................1434 Front Door Lock Switch Inspection............................................................................................................................................................................................1434 Keyless Start Control Module Removal and Installation........................................................................................................................................................................1435 Remote Controller Inspection.................................................................................................................................................................................................1435 Replacement of Remote Controller Battery.....................................................................................................................................................................................1435 Registration Procedure for Remote Controller ID Code.........................................................................................................................................................................1436 COPYRIGHT................................................................................................................................................................................................................................1438 BOOKCOVER_VOL1...........................................................................................................................................................................................................................1439 BOOKCOVER_VOL2...........................................................................................................................................................................................................................1440
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