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Suzuki SX4 RW415 RW416 Service Manual (Vol 1&2) – PDF DOWNLOAD
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Suzuki SX4 RW415 RW416 Service Manual (Vol 1&2) – PDF DOWNLOAD
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Description
Suzuki SX4 RW415 RW416 Service Manual (Vol 1&2) – PDF DOWNLOAD
FILE DETAILS:
Suzuki SX4 RW415 RW416 Service Manual (Vol 1&2) – PDF DOWNLOAD
Language : English
Pages : 1633
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki SX4 RW415 RW416 Service Manual (Vol 1&2) – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
- VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW415/RW416) produced at KOSAI plant in Japan with following vehicle identification number
(VIN) - 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 SX4 RW415 RW416 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 Precautions in Servicing 4WD Model............................................................................................................ 14 Precautions for Catalytic Converter........................................................................................................... 14 Precautions for Installing Mobile Communication Equipment..................................................................................... 15 Precaution for CAN Communication System....................................................................................................... 15 Precautions for Electrical Circuit Service.................................................................................................... 15 Air Bag Warning............................................................................................................................... 17 Air Bag System Service Warning................................................................................................................ 17 Fastener Caution.............................................................................................................................. 18 Suspension Caution............................................................................................................................ 18 Wheels and Tires Caution...................................................................................................................... 18 ABS Caution................................................................................................................................... 18 Precaution for Vehicle Equipped with ESP‚ System.............................................................................................. 18 Brake Caution................................................................................................................................. 18 Repair Instructions............................................................................................................................... 19 Electrical Circuit Inspection Procedure....................................................................................................... 19 Intermittent and Poor Connection Inspection................................................................................................... 21 General Information....................................................................................................................................... 23 General Information................................................................................................................................... 24 General Description............................................................................................................................... 24 Abbreviations................................................................................................................................. 24 Symbols....................................................................................................................................... 25 Wire Color Symbols............................................................................................................................ 25 Fasteners Information......................................................................................................................... 26 Vehicle Lifting Points........................................................................................................................ 28 Vehicle Identification Number................................................................................................................. 29 Engine Identification Number.................................................................................................................. 29 Transmission Identification Number............................................................................................................ 29 Component Location................................................................................................................................ 30 Warning, Caution and Information Labels Location.............................................................................................. 30 Maintenance and Lubrication........................................................................................................................... 32 Precautions....................................................................................................................................... 32 Precautions for Maintenance and Lubrication................................................................................................... 32 Scheduled Maintenance............................................................................................................................. 32 Maintenance Schedule under Normal Driving Conditions.......................................................................................... 32 Maintenance Recommended under Severe Driving Conditions....................................................................................... 33 Repair Instructions............................................................................................................................... 34 Accessory Drive Belt Inspection............................................................................................................... 34 Accessory Drive Belt Replacement.............................................................................................................. 35 Valve Lash (Clearance) Inspection............................................................................................................. 35 Engine Oil and Filter Change.................................................................................................................. 35 Engine Coolant Change......................................................................................................................... 36 Exhaust System Inspection..................................................................................................................... 37 Spark Plug Replacement........................................................................................................................ 37 Air Cleaner Filter Inspection................................................................................................................. 37 Air Cleaner Filter Replacement................................................................................................................ 37 Fuel Lines and Connections Inspection......................................................................................................... 37 Fuel Filter Replacement....................................................................................................................... 37 Fuel Tank Inspection.......................................................................................................................... 38 PCV Valve Inspection.......................................................................................................................... 38 Fuel Evaporative Emission Control System Inspection........................................................................................... 38 Brake Discs and Pads (Front) Inspection....................................................................................................... 38 Brake Drums and Shoes (Rear) Inspection....................................................................................................... 38 Brake Hoses and Pipes Inspection.............................................................................................................. 39 Brake Fluid Replacement....................................................................................................................... 39 Brake Lever and Cable Inspection.............................................................................................................. 39 Clutch Pedal Inspection....................................................................................................................... 39 Clutch Fluid Inspection....................................................................................................................... 39 Tires Inspection.............................................................................................................................. 40 Wheel Discs Inspection........................................................................................................................ 40 Wheel Bearing Inspection...................................................................................................................... 40 Suspension System Inspection.................................................................................................................. 40 Steering System Inspection.................................................................................................................... 40 Drive Shaft (Axle) Boots Inspection........................................................................................................... 41 Propeller Shaft (4WD) Inspection.............................................................................................................. 41 Manual Transaxle Oil Inspection............................................................................................................... 41 Manual Transaxle Oil Replacement.............................................................................................................. 41 Automatic Transaxle Fluid Level Inspection.................................................................................................... 41 Automatic Transaxle Fluid Replacement......................................................................................................... 41 Automatic Transaxle Fluid Cooler Hose Inspection.............................................................................................. 41 Transfer Oil Inspection (4WD)................................................................................................................. 42 Transfer Oil Replacement (4WD)................................................................................................................ 42 Rear Deferential Oil Inspection (4WD)......................................................................................................... 42 Rear Deferential Oil Replacement (4WD)........................................................................................................ 42 All Latches, Hinges and Locks Inspection...................................................................................................... 42 HVAC Air Filter (If Equipped) Inspection...................................................................................................... 42 HVAC Air Filter (If Equipped) Replacement..................................................................................................... 42 Final Inspection for Maintenance Service...................................................................................................... 42 Specifications.................................................................................................................................... 43 Tightening Torque Specifications.............................................................................................................. 43 Special Tools and Equipment....................................................................................................................... 44 Recommended Fluids and Lubricants............................................................................................................. 44 Special Tool.................................................................................................................................. 44 Engine.................................................................................................................................................... 45 Precautions........................................................................................................................................... 50 Precautions....................................................................................................................................... 50 Precautions for Engine........................................................................................................................ 50 Engine General Information and Diagnosis.............................................................................................................. 51 Precautions....................................................................................................................................... 51 Precautions on Engine Service................................................................................................................. 51 Precaution on On-Board Diagnostic (OBD) System................................................................................................ 51 Precautions in Diagnosing Trouble............................................................................................................. 51 Precautions for DTC Troubleshooting........................................................................................................... 52 Precautions of ECM Circuit Inspection......................................................................................................... 52 Precautions of Electric Throttle Body System Calibration...................................................................................... 52 Precaution on CAN Troubleshooting............................................................................................................. 53 General Description............................................................................................................................... 55 Statement on Cleanliness and Care............................................................................................................. 55 Engine Diagnosis General Description.......................................................................................................... 55 On-Board Diagnostic System Description........................................................................................................ 55 Data Link Connector (DLC) Description......................................................................................................... 58 Engine and Emission Control System Description................................................................................................ 58 CAN Communication System Description.......................................................................................................... 59 Air Intake System Description................................................................................................................. 61 Description of Electric Throttle Body System Calibration...................................................................................... 61 Electric Throttle Body System Description..................................................................................................... 61 Electronic Control System Description......................................................................................................... 62 Engine and Emission Control Input / Output Table.............................................................................................. 63 Schematic and Routing Diagram..................................................................................................................... 64 ECM Input / Output Circuit Diagram............................................................................................................ 64 Engine and Emission Control System Flow Diagram............................................................................................... 68 Engine and Emission Control System Diagram.................................................................................................... 69 Component Location................................................................................................................................ 71 Electronic Control System Components Location................................................................................................. 71 Diagnostic Information and Procedures............................................................................................................. 72 Engine and Emission Control System Check...................................................................................................... 72 Malfunction Indicator Lamp (MIL) Check........................................................................................................ 75 DTC Check..................................................................................................................................... 75 DTC Clearance................................................................................................................................. 76 Troubleshooting for Communication Error with Scan Tool Using CAN.............................................................................. 76 DTC Table..................................................................................................................................... 82 Fail-Safe Table............................................................................................................................... 86 Scan Tool Data................................................................................................................................ 88 Visual Inspection............................................................................................................................. 93 Engine Basic Inspection....................................................................................................................... 93 Engine Symptom Diagnosis...................................................................................................................... 95 Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)............................... 102 Malfunction Indicator Lamp Remains ON after Engine Starts..................................................................................... 104 DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system).................................................................... 105 DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system)..................... 107 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1).......................................................................... 109 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2).......................................................................... 111 DTC P0101: Mass Air Flow Circuit Range / Performance.......................................................................................... 113 DTC P0102: Mass Air Flow Circuit Low Input.................................................................................................... 116 DTC P0103: Mass Air Flow Circuit High Input................................................................................................... 117 DTC P0106: Manifold Absolute Pressure Range / Performance..................................................................................... 119 DTC P0107: Manifold Absolute Pressure Circuit Low Input....................................................................................... 120 DTC P0108: Manifold Absolute Pressure Circuit High Input...................................................................................... 122 DTC P0111: Intake Air Temperature Circuit Range / Performance................................................................................. 124 DTC P0112: Intake Air Temperature Sensor Circuit Low.......................................................................................... 126 DTC P0113: Intake Air Temperature Sensor Circuit High......................................................................................... 128 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................. 130 DTC P0117: Engine Coolant Temperature Circuit Low............................................................................................. 133 DTC P0118: Engine Coolant Temperature Circuit High............................................................................................ 134 DTC P0122: Throttle Position Sensor (Main) Circuit Low........................................................................................ 137 DTC P0123: Throttle Position Sensor (Main) Circuit High....................................................................................... 139 DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)............................................................. 142 DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1).................................................................................. 145 DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)........................................................................... 146 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)............................................................. 148 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)........................................................................... 151 DTC P0171 / P0172: Fuel System Too Lean / Rich................................................................................................ 153 DTC P0222: Throttle Position Sensor (Sub) Circuit Low......................................................................................... 155 DTC P0223: Throttle Position Sensor (Sub) Circuit High........................................................................................ 157 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected....... 160 DTC P0327 / P0328: Knock Sensor Circuit Low / High............................................................................................ 162 DTC P0335: Crankshaft Position (CKP) Sensor Circuit........................................................................................... 164 DTC P0340: Camshaft Position (CMP) Sensor Circuit............................................................................................. 166 DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected.................................................. 169 DTC P0403: Exhaust Gas Recirculation Control Circuit.......................................................................................... 172 DTC P0420: Catalyst System Efficiency below Threshold......................................................................................... 174 DTC P0443: Evaporative Emission System Purge Control Valve Circuit............................................................................ 176 DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High....................................................................................... 178 DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit....................................................................................... 179 DTC P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit.................................................................................. 181 DTC P0500: Vehicle Speed Sensor (VSS) Malfunction............................................................................................. 184 DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low........................................................................................ 186 DTC P0533: A/C Refrigerant Pressure Sensor Circuit High....................................................................................... 188 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance..... 189 DTC P0616: Starter Relay Circuit Low.......................................................................................................... 190 DTC P0617: Starter Relay Circuit High......................................................................................................... 191 DTC P1510: ECM Back-Up Power Supply Malfunction............................................................................................... 193 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance........................................................................ 194 DTC P2102: Throttle Actuator Control Motor Circuit Low........................................................................................ 196 DTC P2103: Throttle Actuator Control Motor Circuit High....................................................................................... 197 DTC P2111: Throttle Actuator Control System - Stuck Open...................................................................................... 198 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance........................................................................ 199 DTC P2122: Pedal Position Sensor (Main) Circuit Low Input..................................................................................... 201 DTC P2123: Pedal Position Sensor (Main) Circuit High Input.................................................................................... 203 DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input...................................................................................... 205 DTC P2128: Pedal Position Sensor (Sub) Circuit High Input..................................................................................... 208 DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation.......................................................................... 210 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation............................................................................. 213 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction............................................................................ 215 DTC U0073: Control Module Communication Bus Off............................................................................................... 216 DTC U0101: Lost Communication with TCM........................................................................................................ 216 DTC U0121: Lost Communication with ABS Control Module......................................................................................... 216 DTC U0140: Lost Communication with Body Control Module........................................................................................ 216 Troubleshooting for CAN-DTC................................................................................................................... 217 Inspection of ECM and Its Circuits............................................................................................................ 222 ECM Power and Ground Circuit Check............................................................................................................ 244 Fuel Injector Circuit Check................................................................................................................... 247 Fuel Pump and Its Circuit Check............................................................................................................... 249 Fuel Pressure Check........................................................................................................................... 252 A/C Condenser Cooling Fan Control System Inspection........................................................................................... 253 A/C System Circuits Check..................................................................................................................... 256 Electric Load Signal Circuit Check............................................................................................................ 260 Radiator Cooling Fan Control System Check..................................................................................................... 262 Repair Instructions............................................................................................................................... 263 Idle Speed and IAC Throttle Valve Opening Inspection.......................................................................................... 263 Special Tools and Equipment....................................................................................................................... 264 Special Tool.................................................................................................................................. 264 Aux. Emission Control Devices......................................................................................................................... 265 Diagnostic Information and Procedures............................................................................................................. 265 EGR System Inspection (If Equipped)........................................................................................................... 265 Repair Instructions............................................................................................................................... 265 EVAP Canister Purge Inspection................................................................................................................ 265 EVAP Canister Purge Valve and Its Circuit Inspection.......................................................................................... 265 Vacuum Passage Inspection..................................................................................................................... 266 Vacuum Hose Inspection........................................................................................................................ 267 EVAP Canister Purge Valve Inspection.......................................................................................................... 267 EVAP Canister Inspection...................................................................................................................... 268 EGR Valve Removal and Installation (If Equipped).............................................................................................. 268 EGR Valve Inspection (If Equipped)............................................................................................................ 268 PCV Hose Inspection........................................................................................................................... 269 PCV Valve Inspection.......................................................................................................................... 269 Special Tools and Equipment....................................................................................................................... 269 Special Tool.................................................................................................................................. 269 Engine Electrical Devices............................................................................................................................. 270 Repair Instructions............................................................................................................................... 270 Engine Control Module (ECM) Removal and Installation.......................................................................................... 270 Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped).............................................................................. 271 Electric Throttle Body Assembly On-Vehicle Inspection......................................................................................... 271 Electric Throttle Body System Calibration..................................................................................................... 273 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection........................................................................ 274 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation..................................................................... 274 Accelerator Pedal Position (APP) Sensor Assembly Inspection................................................................................... 274 Engine Coolant Temperature (ECT) Sensor Removal and Installation.............................................................................. 275 Engine Coolant Temperature (ECT) Sensor Inspection............................................................................................ 276 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection (If Equipped)........................................................... 276 Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation (If Equipped)............................................................... 276 Camshaft Position (CMP) Sensor Removal and Installation....................................................................................... 277 Camshaft Position (CMP) Sensor Inspection..................................................................................................... 278 Crankshaft Position (CKP) Sensor Removal and Installation..................................................................................... 278 Crankshaft Position (CKP) Sensor Inspection................................................................................................... 279 Knock Sensor Removal and Installation......................................................................................................... 279 Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay and Radiator Cooling Fan Relay Inspection.......... 280 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................. 280 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation.......................................................... 281 Intake Air Temperature (IAT) Sensor Inspection................................................................................................ 281 Specifications.................................................................................................................................... 282 Tightening Torque Specifications.............................................................................................................. 282 Engine Mechanical..................................................................................................................................... 283 General Description............................................................................................................................... 283 Engine Construction Description............................................................................................................... 283 Camshaft Position Control (VVT Variable Valve Timing) System Description...................................................................... 285 Diagnostic Information and Procedures............................................................................................................. 287 Compression Check............................................................................................................................. 287 Engine Vacuum Check........................................................................................................................... 288 Valve Lash (Clearance) Inspection............................................................................................................. 289 Repair Instructions............................................................................................................................... 292 Air Intake System Components.................................................................................................................. 292 Air Cleaner Filter Removal and Installation................................................................................................... 292 Air Cleaner Filter Inspection and Cleaning.................................................................................................... 292 Air Cleaner Assembly Removal and Installation................................................................................................. 293 Cylinder Head Cover Removal and Installation.................................................................................................. 293 Throttle Body and Intake Manifold Components.................................................................................................. 295 Throttle Body On-Vehicle Inspection........................................................................................................... 296 Electric Throttle Body Assembly Removal and Installation...................................................................................... 296 Throttle Body Cleaning........................................................................................................................ 296 Intake Manifold Removal and Installation...................................................................................................... 297 Engine Mountings Components................................................................................................................... 298 Engine Assembly Removal and Installation...................................................................................................... 299 Timing Chain Cover Components................................................................................................................. 304 Timing Chain Cover Removal and Installation................................................................................................... 305 Timing Chain Cover Inspection................................................................................................................. 307 Oil Control Valve Removal and Installation (For Engine with VVT).............................................................................. 308 Oil Control Valve Inspection (For Engine with VVT)............................................................................................ 308 Timing Chain and Chain Tensioner Components................................................................................................... 309 Timing Chain and Chain Tensioner Removal and Installation..................................................................................... 309 Timing Chain and Chain Tensioner Inspection................................................................................................... 313 Camshaft, Tappet and Shim Components.......................................................................................................... 314 Camshaft, Tappet and Shim Removal and Installation............................................................................................ 315 Camshaft, Tappet and Shim Inspection.......................................................................................................... 318 Valves and Cylinder Head Components........................................................................................................... 321 Valves and Cylinder Head Removal and Installation............................................................................................. 322 Valves and Cylinder Head Disassembly and Assembly............................................................................................. 324 Valves and Valve Guides Inspection............................................................................................................ 327 Cylinder Head Inspection...................................................................................................................... 329 Valve Spring Inspection....................................................................................................................... 330 Pistons, Piston Rings, Connecting Rods and Cylinders Components............................................................................... 330 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................. 331 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly................................................................. 332 Cylinders, Pistons and Piston Rings Inspection................................................................................................ 333 Piston Pins and Connecting Rods Inspection.................................................................................................... 335 Crank Pin and Connecting Rod Bearings Inspection.............................................................................................. 337 Main Bearings, Crankshaft and Cylinder Block Components....................................................................................... 340 Main Bearings, Crankshaft and Cylinder Block Removal and Installation......................................................................... 341 Crankshaft Inspection......................................................................................................................... 344 Main Bearings Inspection...................................................................................................................... 346 Sensor Plate Inspection....................................................................................................................... 350 Rear Oil Seal Inspection...................................................................................................................... 350 Flywheel Inspection........................................................................................................................... 350 Cylinder Block Inspection..................................................................................................................... 350 Specifications.................................................................................................................................... 351 Tightening Torque Specifications.............................................................................................................. 351 Special Tools and Equipment....................................................................................................................... 352 Recommended Service Material.................................................................................................................. 352 Special Tool.................................................................................................................................. 352 Engine Lubrication System............................................................................................................................. 354 General Description............................................................................................................................... 354 Engine Lubrication Description................................................................................................................ 354 Diagnostic Information and Procedures............................................................................................................. 355 Oil Pressure Check............................................................................................................................ 355 Repair Instructions............................................................................................................................... 356 Oil Pan and Oil Pump Strainer Components...................................................................................................... 356 Oil Pan and Oil Pump Strainer Removal and Installation........................................................................................ 357 Oil Pan and Oil Pump Strainer Cleaning........................................................................................................ 358 Oil Pump Components........................................................................................................................... 359 Oil Pump Removal and Installation............................................................................................................. 359 Oil Pump Disassembly and Reassembly........................................................................................................... 359 Oil Pump Inspection........................................................................................................................... 360 Specifications.................................................................................................................................... 362 Tightening Torque Specifications.............................................................................................................. 362 Special Tools and Equipment....................................................................................................................... 362 Recommended Service Material.................................................................................................................. 362 Special Tool.................................................................................................................................. 362 Engine Cooling System................................................................................................................................. 363 General Description............................................................................................................................... 363 Cooling System Description.................................................................................................................... 363 Coolant Description........................................................................................................................... 363 Schematic and Routing Diagram..................................................................................................................... 364 Coolant Circulation........................................................................................................................... 364 Diagnostic Information and Procedures............................................................................................................. 365 Engine Cooling Symptom Diagnosis.............................................................................................................. 365 Repair Instructions............................................................................................................................... 366 Cooling System Components..................................................................................................................... 366 Coolant Level Check........................................................................................................................... 367 Engine Cooling System Inspection and Cleaning................................................................................................. 367 Cooling System Draining....................................................................................................................... 367 Cooling System Flush and Refill............................................................................................................... 368 Cooling Water Pipes or Hoses Removal and Installation......................................................................................... 368 Thermostat Removal and Installation........................................................................................................... 369 Thermostat Inspection......................................................................................................................... 369 Radiator Cooling Fan Assembly On-Vehicle Inspection........................................................................................... 370 Radiator Cooling Fan Relay Inspection......................................................................................................... 370 Radiator Cooling Fan Assembly Removal and Installation........................................................................................ 370 Radiator Cooling Fan Disassembly and Reassembly............................................................................................... 371 Radiator On-Vehicle Inspection and Cleaning................................................................................................... 371 Radiator Removal and Installation............................................................................................................. 371 Water Pump / Generator Drive Belt Tension Inspection and Adjustment........................................................................... 372 Water Pump / Generator Drive Belt Removal and Installation.................................................................................... 372 Water Pump Removal and Installation........................................................................................................... 373 Water Pump Inspection......................................................................................................................... 374 Specifications.................................................................................................................................... 374 Tightening Torque Specifications.............................................................................................................. 374 Special Tools and Equipment....................................................................................................................... 374 Recommended Service Material.................................................................................................................. 374 Fuel System........................................................................................................................................... 375 Precautions....................................................................................................................................... 375 Precautions on Fuel System Service............................................................................................................ 375 General Description............................................................................................................................... 376 Fuel System Description....................................................................................................................... 376 Fuel Delivery System Description.............................................................................................................. 376 Fuel Pump Description......................................................................................................................... 376 Schematic and Routing Diagram..................................................................................................................... 377 Fuel Delivery System Diagram.................................................................................................................. 377 Diagnostic Information and Procedures............................................................................................................. 377 Fuel Pressure Inspection...................................................................................................................... 377 Fuel Cut Operation Inspection................................................................................................................. 378 Repair Instructions............................................................................................................................... 379 Fuel System Components........................................................................................................................ 379 Fuel Hose Disconnecting and Reconnecting...................................................................................................... 380 Fuel Pressure Relief Procedure................................................................................................................ 381 Fuel Leakage Check Procedure.................................................................................................................. 382 Fuel Lines On-Vehicle Inspection.............................................................................................................. 382 Fuel Pipe Removal and Installation............................................................................................................ 382 Fuel Injector On-Vehicle Inspection........................................................................................................... 383 Fuel Injector Removal and Installation........................................................................................................ 383 Fuel Injector Inspection...................................................................................................................... 384 Fuel Filler Cap Inspection.................................................................................................................... 386 Fuel Tank Inlet Valve Removal and Installation................................................................................................ 386 Fuel Tank Inlet Valve Inspection.............................................................................................................. 386 Fuel Tank Removal and Installation............................................................................................................ 387 Fuel Tank Inspection.......................................................................................................................... 388 Fuel Tank Purging Procedure................................................................................................................... 389 Fuel Pump On-Vehicle Inspection............................................................................................................... 389 Fuel Pump Assembly Removal and Installation................................................................................................... 389 Main Fuel Level Sensor Removal and Installation............................................................................................... 390 Fuel Pump Inspection.......................................................................................................................... 391 Specifications.................................................................................................................................... 391 Tightening Torque Specifications.............................................................................................................. 391 Special Tools and Equipment....................................................................................................................... 392 Special Tool.................................................................................................................................. 392 Ignition System....................................................................................................................................... 393 General Description............................................................................................................................... 393 Ignition System Construction.................................................................................................................. 393 Schematic and Routing Diagram..................................................................................................................... 394 Ignition System Wiring Circuit Diagram........................................................................................................ 394 Component Location................................................................................................................................ 395 Ignition System Components Location........................................................................................................... 395 Diagnostic Information and Procedures............................................................................................................. 396 Ignition System Symptom Diagnosis............................................................................................................. 396 Reference Waveform of Ignition System......................................................................................................... 396 Ignition System Check......................................................................................................................... 396 Ignition Spark Test........................................................................................................................... 398 Repair Instructions............................................................................................................................... 398 High-Tension Cord Removal and Installation.................................................................................................... 398 High-Tension Cord Inspection.................................................................................................................. 399 Spark Plug Removal and Installation........................................................................................................... 399 Spark Plug Inspection......................................................................................................................... 399 Ignition Coil Assembly (Including Ignitor) Removal and Installation........................................................................... 400 Ignition Coil Assembly (Including Ignitor) Inspection......................................................................................... 400 Ignition Timing Inspection.................................................................................................................... 400 Specifications.................................................................................................................................... 401 Tightening Torque Specifications.............................................................................................................. 401 Special Tools and Equipment....................................................................................................................... 401 Special Tool.................................................................................................................................. 401 Starting System....................................................................................................................................... 402 Schematic and Routing Diagram..................................................................................................................... 402 Cranking System Circuit Diagram............................................................................................................... 402 Diagnostic Information and Procedures............................................................................................................. 402 Cranking System Symptom Diagnosis............................................................................................................. 402 Cranking System Test.......................................................................................................................... 404 Repair Instructions............................................................................................................................... 405 Starting Motor Dismounting and Remounting..................................................................................................... 405 Starting Motor Components..................................................................................................................... 406 Starting Motor Inspection..................................................................................................................... 407 Specifications.................................................................................................................................... 410 Cranking System Specifications................................................................................................................ 410 Tightening Torque Specifications.............................................................................................................. 410 Special Tools and Equipment....................................................................................................................... 410 Recommended Service Material.................................................................................................................. 410 Charging System....................................................................................................................................... 411 General Description............................................................................................................................... 411 Battery Description........................................................................................................................... 411 Generator Description......................................................................................................................... 412 Diagnostic Information and Procedures............................................................................................................. 413 Battery Inspection............................................................................................................................ 413 Generator Symptom Diagnosis................................................................................................................... 414 Generator Test (Undercharged Battery Check)................................................................................................... 414 Generator Test (Overcharged Battery Check).................................................................................................... 415 Repair Instructions............................................................................................................................... 416 Jump Starting in Case of Emergency............................................................................................................ 416 Battery Dismounting and Remounting............................................................................................................ 416 Water Pump / Generator Drive Belt Tension Inspection and Adjustment........................................................................... 417 Water Pump / Generator Drive Belt Removal and Installation.................................................................................... 418 Generator Dismounting and Remounting.......................................................................................................... 418 Generator Components.......................................................................................................................... 419 Generator Inspection.......................................................................................................................... 420 Specifications.................................................................................................................................... 422 Charging System Specifications................................................................................................................ 422 Tightening Torque Specifications.............................................................................................................. 422 Exhaust System........................................................................................................................................ 423 General Description............................................................................................................................... 423 Exhaust System Description.................................................................................................................... 423 Diagnostic Information and Procedures............................................................................................................. 423 Exhaust System Check.......................................................................................................................... 423 Repair Instructions............................................................................................................................... 424 Exhaust System Components..................................................................................................................... 424 Exhaust Manifold Removal and Installation..................................................................................................... 425 Exhaust Pipe and Muffler Removal and Installation............................................................................................. 426 Specifications.................................................................................................................................... 426 Tightening Torque Specifications.............................................................................................................. 426 Suspension................................................................................................................................................ 427 Precautions........................................................................................................................................... 429 Precautions....................................................................................................................................... 429 Precautions on Suspension..................................................................................................................... 429 Suspension General Diagnosis.......................................................................................................................... 430 Diagnostic Information and Procedures............................................................................................................. 430 Suspension, Wheels and Tires Symptom Diagnosis................................................................................................ 430 Front Suspension...................................................................................................................................... 432 General Description............................................................................................................................... 432 Front Suspension Construction................................................................................................................. 432 Front Wheel Alignment Construction............................................................................................................ 433 Repair Instructions............................................................................................................................... 433 Front Wheel Alignment Inspection and Adjustment............................................................................................... 433 Camber and Caster Check....................................................................................................................... 434 Steering Angle Check and Adjustment........................................................................................................... 435 Front Strut Assembly Components............................................................................................................... 435 Front Strut Assembly Removal and Installation................................................................................................. 436 Front Strut Assembly Disassembly and Reassembly............................................................................................... 437 Front Strut Assembly Check.................................................................................................................... 438 Front Wheel Hub and Steering Knuckle Components............................................................................................... 439 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation.................................................................. 439 Front Wheel Bearing and Wheel Hub Inspection.................................................................................................. 443 Suspension Control Arm Removal and Installation............................................................................................... 444 Suspension Control Arm Bush Disassembly and Assembly.......................................................................................... 444 Suspension Control Arm / Steering Knuckle Check............................................................................................... 445 Suspension Control Arm Bush Inspection........................................................................................................ 445 Suspension Control Arm Joint Check............................................................................................................ 445 Front Suspension Frame, Stabilizer Bar and/or Bush Components................................................................................. 446 Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation................................................................... 446 Front Suspension Frame Check.................................................................................................................. 449 Front Stabilizer Bar, Bush and/or Joint Check................................................................................................. 449 Front Suspension Fasteners Check.............................................................................................................. 449 Specifications.................................................................................................................................... 450 Tightening Torque Specifications.............................................................................................................. 450 Special Tools and Equipment....................................................................................................................... 451 Recommended Service Material.................................................................................................................. 451 Special Tool.................................................................................................................................. 451 Rear Suspension....................................................................................................................................... 452 Repair Instructions............................................................................................................................... 452 Rear Suspension Components.................................................................................................................... 452 Rear Wheel Alignment Inspection............................................................................................................... 453 Rear Shock Absorber Removal and Installation.................................................................................................. 453 Rear Shock Absorber Inspection................................................................................................................ 455 Rear Shock Absorber Bush Inspection........................................................................................................... 455 Rear Coil Spring Removal and Installation..................................................................................................... 455 Spring Upper Seat / Spring Lower Seat Inspection.............................................................................................. 457 Rear Axle Removal and Installation............................................................................................................ 457 Rear Axle and Coil Spring Inspection.......................................................................................................... 458 Rear Axle Bush Inspection..................................................................................................................... 458 Rear Wheel Hub Assembly Inspection............................................................................................................ 459 Rear Wheel Hub Assembly Removal and Installation.............................................................................................. 459 Specifications.................................................................................................................................... 461 Tightening Torque Specifications.............................................................................................................. 461 Wheels and Tires...................................................................................................................................... 462 Precautions....................................................................................................................................... 462 Precautions in Wheels and Tires Servicing..................................................................................................... 462 General Description............................................................................................................................... 462 Tires Description............................................................................................................................. 462 Wheels Description............................................................................................................................ 463 Irregular and/or Premature Wear Description................................................................................................... 464 Wear Indicators Description................................................................................................................... 464 Radial Tire Waddle Description................................................................................................................ 464 Radial Tire Lead / Pull Description........................................................................................................... 465 Balancing Wheels Description.................................................................................................................. 465 Repair Instructions............................................................................................................................... 466 Wheel Discs Inspection........................................................................................................................ 466 Wheel Balance Inspection and Adjustment....................................................................................................... 466 Tire Rotation................................................................................................................................. 466 Wheel (with Tire) Removal and Installation.................................................................................................... 466 Tire Mounting and Dismounting................................................................................................................. 467 Tire Repair................................................................................................................................... 467 Specifications.................................................................................................................................... 467 Wheels and Tires Specifications............................................................................................................... 467 Tightening Torque Specifications.............................................................................................................. 467 Driveline / Axle.......................................................................................................................................... 469 Precautions........................................................................................................................................... 471 Precautions....................................................................................................................................... 471 Precautions on Driveline / Axle............................................................................................................... 471 Drive Shaft / Axle.................................................................................................................................... 472 Front............................................................................................................................................. 472 General Description........................................................................................................................... 472 Front Drive Shaft Construction............................................................................................................ 472 Component Location............................................................................................................................ 472 Front Drive Shaft Assembly Components Location............................................................................................ 472 Diagnostic Information and Procedures......................................................................................................... 473 Front Drive Shaft Symptom Diagnosis....................................................................................................... 473 Repair Instructions........................................................................................................................... 473 Front Drive Shaft Components.............................................................................................................. 473 Front Drive Shaft Assembly On-Vehicle Inspection.......................................................................................... 474 Front Drive Shaft Assembly Removal and Installation....................................................................................... 474 Front Drive Shaft Disassembly and Reassembly.............................................................................................. 475 Center Shaft and Center Bearing Support Disassembly and Reassembly (If Equipped).......................................................... 483 Specifications................................................................................................................................ 484 Tightening Torque Specifications.......................................................................................................... 484 Special Tools and Equipment................................................................................................................... 485 Recommended Service Material.............................................................................................................. 485 Special Tool.............................................................................................................................. 485 Rear.............................................................................................................................................. 486 General Description........................................................................................................................... 486 Rear Drive Shaft Construction............................................................................................................. 486 Repair Instructions........................................................................................................................... 486 Rear Drive Shaft Components............................................................................................................... 486 Rear Drive Shaft Assembly Removal and Installation........................................................................................ 487 Rear Drive Shaft Disassembly and Reassembly............................................................................................... 487 Specifications................................................................................................................................ 489 Tightening Torque Specifications.......................................................................................................... 489 Special Tools and Equipment................................................................................................................... 489 Recommended Service Material.............................................................................................................. 489 Special Tool.............................................................................................................................. 489 Differential.......................................................................................................................................... 490 Precautions....................................................................................................................................... 490 Precaution for Rear Differential Oil Leakage.................................................................................................. 490 Precautions in Diagnosing Trouble............................................................................................................. 490 General Description............................................................................................................................... 491 Rear Differential Description................................................................................................................. 491 Coupling Description.......................................................................................................................... 491 4WD Control System Description................................................................................................................ 492 Function of 4WD Control System Component...................................................................................................... 492 Input / Output Signal Table of 4WD Control Module............................................................................................. 493 On-Board Diagnostic System Description........................................................................................................ 493 CAN Communication System Description.......................................................................................................... 494 Schematic and Routing Diagram..................................................................................................................... 495 4WD Control System Wiring Circuit Diagram..................................................................................................... 495 Component Location................................................................................................................................ 497 4WD Control System Components Location........................................................................................................ 497 Diagnostic Information and Procedures............................................................................................................. 498 4WD Control System Check...................................................................................................................... 498 4WD Position Indicator Operation Check........................................................................................................ 500 4WD Control System Operation Inspection....................................................................................................... 500 Visual Inspection............................................................................................................................. 501 DTC Check..................................................................................................................................... 501 DTC Clearance................................................................................................................................. 501 DTC Table..................................................................................................................................... 502 Fail-Safe Table............................................................................................................................... 502 Scan Tool Data................................................................................................................................ 503 Rear Differential Symptom Diagnosis........................................................................................................... 504 4WD Control Symptom Diagnosis................................................................................................................. 504 4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops................................................................ 505 4WD Position Indicator Remains ON Steady at Ignition Switch ON................................................................................ 506 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction................................................................................ 507 DTC C1243: Internal Circuit Malfunction of 4WD Control Module................................................................................. 508 DTC C1250: Coupling Air Temperature Sensor Circuit Open....................................................................................... 508 DTC C1251: Coupling Air Temperature Sensor Circuit Short...................................................................................... 510 DTC C1252: Coupling Assembly Circuit Open..................................................................................................... 511 DTC C1253: Coupling Assembly Circuit Short.................................................................................................... 513 DTC C1254: 2WD/4WD Switch Malfunction......................................................................................................... 514 DTC U0073: Control Module Communication Bus Off............................................................................................... 516 DTC U0100: Lost Communication with ECM........................................................................................................ 516 DTC U0121: Lost Communication with ABS / ESP‚ Control Module.................................................................................. 516 DTC U0155: Lost Communication with Instrument Panel Cluster (IPC) Control Module.............................................................. 516 Inspection of 4WD Control Module and Its Circuits............................................................................................. 516 Repair Instructions............................................................................................................................... 519 Rear Differential Oil Level Check............................................................................................................. 519 Rear Differential Oil Change.................................................................................................................. 519 2WD/4WD Switch Removal and Installation....................................................................................................... 520 2WD/4WD Switch Inspection..................................................................................................................... 520 4WD Control Module Removal and Installation................................................................................................... 520 Coupling Air Temperature Sensor Removal and Installation...................................................................................... 520 Coupling Air Temperature Sensor Inspection.................................................................................................... 521 Coupling Assembly Inspection.................................................................................................................. 521 Rear Differential Mountings Components........................................................................................................ 522 Front Mounting Arm and/or Rear Mounting Bracket Assembly Removal and Installation............................................................. 523 Rear Mounting Bracket Assembly Disassembly and Reassembly..................................................................................... 523 Rear Differential Dismounting and Remounting.................................................................................................. 523 Rear Differential Components.................................................................................................................. 524 Rear Differential Disassembly and Reassembly.................................................................................................. 525 Rear Differential Inspection.................................................................................................................. 536 Specifications.................................................................................................................................... 537 Tightening Torque Specifications.............................................................................................................. 537 Special Tools and Equipment....................................................................................................................... 537 Recommended Service Material.................................................................................................................. 537 Special Tool.................................................................................................................................. 538 Transfer.............................................................................................................................................. 540 General Description............................................................................................................................... 540 Transfer Description.......................................................................................................................... 540 Diagnostic Information and Procedures............................................................................................................. 540 Transfer Symptom Diagnosis.................................................................................................................... 540 Repair Instructions............................................................................................................................... 541 Transfer Oil Level Check...................................................................................................................... 541 Transfer Oil Change........................................................................................................................... 541 Transfer Dismounting and Remounting........................................................................................................... 542 Transfer Assembly Components.................................................................................................................. 543 Transfer Assembly Disassembly and Reassembly.................................................................................................. 544 Reduction Drive Gear Assembly Disassembly and Reassembly...................................................................................... 546 Reduction Driven Gear Assembly Disassembly and Reassembly..................................................................................... 547 Transfer Right Case and Left Case Disassembly and Reassembly.................................................................................. 548 Transfer Output Retainer Assembly Disassembly and Reassembly.................................................................................. 549 Transfer Assembly Inspection.................................................................................................................. 553 Bevel Gear Tooth Contact Inspection........................................................................................................... 553 Specifications.................................................................................................................................... 555 Tightening Torque Specifications.............................................................................................................. 555 Special Tools and Equipment....................................................................................................................... 556 Recommended Service Material.................................................................................................................. 556 Special Tool.................................................................................................................................. 556 Propeller Shaft....................................................................................................................................... 558 Precautions....................................................................................................................................... 558 Propeller Shaft Caution....................................................................................................................... 558 General Description............................................................................................................................... 558 Propeller Shaft Construction.................................................................................................................. 558 Diagnostic Information and Procedures............................................................................................................. 558 Propeller Shaft Symptom Diagnosis............................................................................................................. 558 Repair Instructions............................................................................................................................... 559 Propeller Shaft Joint Check................................................................................................................... 559 Propeller Shaft Assembly Removal and Installation............................................................................................. 559 Propeller Shaft Inspection.................................................................................................................... 559 Specifications.................................................................................................................................... 560 Tightening Torque Specifications.............................................................................................................. 560 Brakes.................................................................................................................................................... 561 Precautions........................................................................................................................................... 564 Precautions....................................................................................................................................... 564 Precautions for Brakes........................................................................................................................ 564 Brake Control System and Diagnosis.................................................................................................................... 565 Precautions....................................................................................................................................... 565 Precautions on Brake.......................................................................................................................... 565 General Description............................................................................................................................... 565 Brakes Construction........................................................................................................................... 565 Brake Pedal Foot Protection System Construction (If Equipped)................................................................................. 566 Diagnostic Information and Procedures............................................................................................................. 566 Brakes Diagnosis Note......................................................................................................................... 566 Brakes Symptom Diagnosis...................................................................................................................... 567 Repair Instructions............................................................................................................................... 569 Brake Pedal Components........................................................................................................................ 569 Brake Pedal Free Height Inspection............................................................................................................ 569 Brake Pedal Play Inspection................................................................................................................... 569 Excessive Pedal Travel Inspection............................................................................................................. 570 Brake Fluid Level Inspection.................................................................................................................. 570 Brake Light Switch Adjustment................................................................................................................. 571 Air Bleeding of Brake System.................................................................................................................. 571 Front Brake Hose / Pipe Components............................................................................................................ 572 Front Brake Hose and Pipe Removal and Installation............................................................................................ 573 Rear Brake Hose / Pipe Components............................................................................................................. 574 Rear Brake Hose and Pipe Removal and Installation............................................................................................. 574 Brake Hose and Pipe Inspection................................................................................................................ 574 Master Cylinder and Brake Booster Components.................................................................................................. 575 Master Cylinder Reservoir Removal and Installation............................................................................................ 576 Master Cylinder Removal and Installation...................................................................................................... 577 Master Cylinder Inspection.................................................................................................................... 578 Booster Operation Inspection.................................................................................................................. 578 Brake Booster Removal and Installation........................................................................................................ 580 Brake Booster Inspection...................................................................................................................... 580 Booster Push Clevis Rod Adjustment............................................................................................................ 580 Specifications.................................................................................................................................... 581 Tightening Torque Specifications.............................................................................................................. 581 Special Tools and Equipment....................................................................................................................... 581 Recommended Service Material.................................................................................................................. 581 Special Tool.................................................................................................................................. 581 Front Brakes.......................................................................................................................................... 582 Repair Instructions............................................................................................................................... 582 Front Disc Brake Components................................................................................................................... 582 Front Disc Brake Pad On-Vehicle Inspection.................................................................................................... 583 Front Disc Brake Pad Removal and Installation................................................................................................. 583 Front Disc Brake Pad Inspection............................................................................................................... 584 Front Disc Brake Caliper Removal and Installation............................................................................................. 584 Front Disc Brake Caliper Disassembly and Assembly............................................................................................. 585 Front Disc Brake Caliper Check................................................................................................................ 587 Front Brake Disc Removal and Installation..................................................................................................... 587 Front Brake Disc Inspection................................................................................................................... 588 Specifications.................................................................................................................................... 589 Tightening Torque Specifications.............................................................................................................. 589 Special Tools and Equipment....................................................................................................................... 589 Recommended Service Material.................................................................................................................. 589 Special Tool.................................................................................................................................. 589 Rear Brakes........................................................................................................................................... 590 Repair Instructions............................................................................................................................... 590 Rear Drum Brake Components.................................................................................................................... 590 Rear Brake Drum Removal and Installation...................................................................................................... 591 Rear Brake Drum and Shoe Inspection........................................................................................................... 591 Rear Brake Shoe On-Vehicle Inspection......................................................................................................... 592 Rear Brake Shoe Removal and Installation...................................................................................................... 592 Rear Brake Adjuster and Shoe Lever Check...................................................................................................... 593 Wheel Cylinder Removal and Installation....................................................................................................... 593 Wheel Cylinder Inspection..................................................................................................................... 594 Brake Back Plate Removal and Installation..................................................................................................... 594 Specifications.................................................................................................................................... 595 Tightening Torque Specifications.............................................................................................................. 595 Special Tools and Equipment....................................................................................................................... 595 Recommended Service Material.................................................................................................................. 595 Parking Brake......................................................................................................................................... 596 Repair Instructions............................................................................................................................... 596 Parking Brake Cable Components................................................................................................................ 596 Parking Brake Inspection and Adjustment....................................................................................................... 597 Parking Brake Cable Removal and Installation.................................................................................................. 597 Parking Brake Lever Removal and Installation.................................................................................................. 598 Specifications.................................................................................................................................... 599 Tightening Torque Specifications.............................................................................................................. 599 ABS................................................................................................................................................... 600 Precautions....................................................................................................................................... 600 Precautions in Diagnosing Troubles............................................................................................................ 600 Precautions in On-Vehicle Service............................................................................................................. 600 General Description............................................................................................................................... 601 ABS Description............................................................................................................................... 601 ABS Hydraulic Unit / Control Module Assembly Description...................................................................................... 602 CAN Communication System Description.......................................................................................................... 602 Schematic and Routing Diagram..................................................................................................................... 603 ABS Schematic................................................................................................................................. 603 ABS Wiring Circuit Diagram.................................................................................................................... 604 Component Location................................................................................................................................ 606 ABS Components Location....................................................................................................................... 606 Diagnostic Information and Procedures............................................................................................................. 607 ABS Check..................................................................................................................................... 607 ABS Warning Light Check....................................................................................................................... 609 EBD Warning Light (Brake Warning Light) Check................................................................................................. 609 DTC Check..................................................................................................................................... 610 DTC Table..................................................................................................................................... 610 DTC Clearance................................................................................................................................. 610 Scan Tool Data................................................................................................................................ 611 ABS Warning Light Does Not Come ON at Ignition Switch ON...................................................................................... 612 ABS Warning Light Comes ON Steady............................................................................................................. 614 EBD Warning Light (Brake Warning Light) Comes ON Steady....................................................................................... 615 Serial Data Link Circuit Check................................................................................................................ 616 DTC C1013: Control Module Mismatch............................................................................................................ 619 DTC C1015: G Sensor Circuit (4WD Model)....................................................................................................... 620 DTC 1016: Brake Light Switch.................................................................................................................. 621 DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder............................. 622 DTC C1033: Wheel Speed Sensor Deviation....................................................................................................... 624 DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid.................................................... 625 DTC C1057: Power Supply Voltage Too High / Too Low............................................................................................ 626 DTC C1061: Pump Motor Circuit................................................................................................................. 627 DTC C1063: Solenoid Valve Power Supply Driver Circuit......................................................................................... 628 DTC C1071: Control Module Internal Defect..................................................................................................... 629 ABS Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check................................................................... 629 Repair Instructions............................................................................................................................... 630 ABS Hydraulic Unit Operation Check............................................................................................................ 630 ABS Hydraulic Unit / Control Module Assembly Components....................................................................................... 631 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection............................................................................ 632 ABS Hydraulic Unit / Control Module Assembly Removal and Installation......................................................................... 632 Front and Rear Wheel Speed Sensor On-Vehicle Inspection....................................................................................... 633 Front Wheel Speed Sensor Removal and Installation............................................................................................. 634 Front and Rear Wheel Speed Sensor Inspection.................................................................................................. 635 Rear Wheel Speed Sensor Removal and Installation (4WD Model).................................................................................. 635 Rear Wheel Speed Sensor Removal and Installation (2WD Model).................................................................................. 635 Front Wheel Speed Sensor Encoder On-Vehicle Inspection........................................................................................ 636 Front Wheel Speed Sensor Encoder Removal and Installation..................................................................................... 636 Rear Wheel Speed Sensor Encoder On-Vehicle Inspection......................................................................................... 636 Rear Wheel Speed Sensor Encoder Removal and Installation...................................................................................... 636 G Sensor Removal and Installation (4WD Model)................................................................................................. 637 G Sensor Inspection (4WD Model)............................................................................................................... 637 Specifications.................................................................................................................................... 638 Tightening Torque Specifications.............................................................................................................. 638 Special Tools and Equipment....................................................................................................................... 638 Special Tool.................................................................................................................................. 638 Electronic Stability Program.......................................................................................................................... 639 Precautions....................................................................................................................................... 639 Precautions in Diagnosing Troubles............................................................................................................ 639 Precautions in On-Vehicle Service............................................................................................................. 639 Precautions in Hydraulic Unit Operation Check................................................................................................. 639 Precautions in Sensor Calibration............................................................................................................. 639 Precautions in Speedometer Test or Other Tests................................................................................................ 640 General Description............................................................................................................................... 640 Electronic Stability Program System Description............................................................................................... 640 Electronic Stability Program Construction..................................................................................................... 641 Components of Electronic Stability Program.................................................................................................... 641 On-Board Diagnosis System Description......................................................................................................... 643 Warning Light, Indicator Light Description.................................................................................................... 644 CAN Communication System Description.......................................................................................................... 645 Schematic and Routing Diagram..................................................................................................................... 646 Electronic Stability Program Schematic........................................................................................................ 646 Electronic Stability Program Wiring Circuit Diagram........................................................................................... 647 Component Location................................................................................................................................ 648 Electronic Stability Program Component Location............................................................................................... 648 Diagnostic Information and Procedures............................................................................................................. 650 Electronic Stability Program Check............................................................................................................ 650 ESP‚ Warning Light Check...................................................................................................................... 652 ABS Warning Light Check....................................................................................................................... 652 EBD Warning Light (Brake Warning Light) Check................................................................................................. 652 DTC Check..................................................................................................................................... 653 DTC Table..................................................................................................................................... 653 DTC Clearance................................................................................................................................. 657 Fail-Safe Table............................................................................................................................... 657 Scan Tool Data................................................................................................................................ 659 Visual Inspection............................................................................................................................. 660 ESP‚ Warning Light Does Not Come ON at Ignition Switch ON..................................................................................... 661 ESP‚ Warning Light Comes ON Steady............................................................................................................ 662 ABS Warning Light Does Not Come ON at Ignition Switch ON...................................................................................... 663 ABS Warning Light Comes ON Steady............................................................................................................. 663 EBD Warning Light (Brake Warning Light) Comes ON Steady....................................................................................... 664 Serial Data Link Circuit Check................................................................................................................ 666 DTC C1016: Brake Light Switch................................................................................................................. 668 DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor......................................................................................... 670 DTC C1020 / C1028: Master Cylinder Pressure Sensor Power Supply Failure / Circuit............................................................. 670 DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder............................. 671 DTC C1024: Steering Angle Sensor.............................................................................................................. 673 DTC C1027: ESP‚ OFF Switch.................................................................................................................... 673 DTC C1033: Wheel Speed Sensor Deviation....................................................................................................... 674 DTC C1034 / C1039: Yaw Rate / G Sensor Power Supply Failure / Internal Failure................................................................ 676 DTC C1037: Steering Angle Sensor Power Supply Failure......................................................................................... 677 DTC C1038: Steering Angle Sensor Detect Rolling Counter....................................................................................... 678 DTC C1040: ESP‚ Continuous Operation.......................................................................................................... 679 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet / Outlet / Cut / Suction Solenoid.... 679 DTC C1057: Power Supply Voltage Too High / Too Low............................................................................................ 681 DTC C1061: Pump Motor Circuit................................................................................................................. 682 DTC C1063: Solenoid Valve Power Supply Driver Circuit......................................................................................... 683 DTC C1071: Control Module Internal Defect..................................................................................................... 684 DTC C1075: Steering Angle Sensor Calibration.................................................................................................. 684 DTC C1091: CAN Invalid Data from ECM.......................................................................................................... 685 DTC C1096: Yaw Rate / G Sensor Message Counter Error.......................................................................................... 685 DTC U0073: Control Module Communication Bus Off............................................................................................... 686 DTC U0100: Lost Communication with ECM / PCM.................................................................................................. 686 DTC U0101: Lost Communication with TCM........................................................................................................ 686 DTC U0114: Lost Communication with Four-Wheel Drive Clutch Control Module..................................................................... 686 DTC U0123: Lost Communication with Yaw Rate Sensor Module..................................................................................... 686 DTC U0126: Lost Communication with Steering Angle Sensor...................................................................................... 686 ESP‚ Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check.................................................................. 686 Repair Instructions............................................................................................................................... 688 ESP‚ Hydraulic Unit Operation Check........................................................................................................... 688 Sensor Calibration............................................................................................................................ 688 ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................... 689 ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................ 689 Front Wheel Speed Sensor On-Vehicle Inspection................................................................................................ 691 Front Wheel Speed Sensor Removal and Installation............................................................................................. 691 Front Wheel Speed Sensor Inspection........................................................................................................... 691 Rear Wheel Speed Sensor On-Vehicle Inspection................................................................................................. 691 Rear Wheel Speed Sensor Removal and Installation.............................................................................................. 691 Rear Wheel Speed Sensor Inspection............................................................................................................ 691 Front Wheel Speed Sensor Encoder On-Vehicle Inspection........................................................................................ 691 Front Wheel Speed Sensor Encoder Removal and Installation..................................................................................... 691 Rear Wheel Speed Sensor Encoder On-Vehicle Inspection......................................................................................... 691 Rear Wheel Speed Sensor Encoder Removal and Installation...................................................................................... 691 Master Cylinder Pressure Sensor On-Vehicle Inspection......................................................................................... 691 Yaw Rate / G Sensor On-Vehicle Inspection..................................................................................................... 692 Yaw Rate / G Sensor Removal and Installation.................................................................................................. 693 Yaw Rate / G Sensor Inspection................................................................................................................ 694 Steering Angle Sensor On-Vehicle Inspection................................................................................................... 694 Steering Angle Sensor Removal and Installation................................................................................................ 695 Steering Angle Sensor Inspection.............................................................................................................. 695 ESP‚ OFF Switch Removal and Installation...................................................................................................... 695 ESP‚ OFF Switch Inspection.................................................................................................................... 695 Specifications.................................................................................................................................... 696 Tightening Torque Specifications.............................................................................................................. 696 Special Tools and Equipment....................................................................................................................... 696 Special Tool.................................................................................................................................. 696 Transmission / Transaxle.................................................................................................................................. 697 Precautions........................................................................................................................................... 700 Precautions....................................................................................................................................... 700 Precautions on Transmission / Transaxle....................................................................................................... 700 Automatic Transmission/Transaxle...................................................................................................................... 701 Precautions....................................................................................................................................... 701 Precautions in Diagnosing Trouble............................................................................................................. 701 Precautions for Disassembly and Reassembly.................................................................................................... 701 General Description............................................................................................................................... 703 A/T Description............................................................................................................................... 703 Clutch / Brake / Planetary Gear Function of Automatic Transaxle............................................................................... 707 Table of Component Operation.................................................................................................................. 708 Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve.............................................................. 708 Automatic Gear Shift Table.................................................................................................................... 709 A/T Diagnosis General Description............................................................................................................. 711 On-Board Diagnostic System Description........................................................................................................ 711 CAN Communication System Description.......................................................................................................... 712 Schematic and Routing Diagram..................................................................................................................... 713 Transmission Control Module (TCM) Wiring Diagram.............................................................................................. 713 A/T System Diagram............................................................................................................................ 715 Component Location................................................................................................................................ 716 Electronic Shift Control System Components Location........................................................................................... 716 Diagnostic Information and Procedures............................................................................................................. 717 A/T System Check.............................................................................................................................. 717 Visual Inspection............................................................................................................................. 719 Malfunction Indicator Lamp (MIL) Check........................................................................................................ 720 Transmission Warning Light Check (Non-Euro-OBD model)......................................................................................... 720 DTC Table..................................................................................................................................... 720 DTC Check..................................................................................................................................... 722 DTC Clearance................................................................................................................................. 723 Fail-Safe Table............................................................................................................................... 723 Scan Tool Data................................................................................................................................ 725 A/T Basic Check............................................................................................................................... 728 Road Test..................................................................................................................................... 728 Manual Road Test.............................................................................................................................. 731 Engine Brake Test............................................................................................................................. 731 Stall Test.................................................................................................................................... 732 Time Lag Test................................................................................................................................. 733 Line Pressure Test............................................................................................................................ 734 “P” Range Test................................................................................................................................ 735 A/T Symptom Diagnosis......................................................................................................................... 735 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON (Non-Euro- OBD Model)..................................... 743 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON (Non- Euro-OBD Model)............................... 743 DTC P0602: Control Module Programming Error................................................................................................... 744 DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input)........................................................................ 744 DTC P0707: Transmission Range Sensor Circuit Low.............................................................................................. 746 DTC P0711: Transmission Fluid Temperature Sensor “A” Control Range / Performance.............................................................. 748 DTC P0712: Transmission Fluid Temperature Sensor Circuit Low.................................................................................. 749 DTC P0713: Transmission Fluid Temperature Sensor Circuit High................................................................................. 750 DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction................................................................................... 752 DTC P0722: Output Speed Sensor (VSS) Circuit No Signal........................................................................................ 753 DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON................................................................ 755 DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction................................................................................. 756 DTC P0787: Shift / Timing Solenoid Control Circuit Low........................................................................................ 757 DTC P0788: Shift / Timing Solenoid Control Circuit High....................................................................................... 759 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance.................................................................. 760 DTC P0962: Pressure Control Solenoid Control Circuit Low...................................................................................... 762 DTC P0963: Pressure Control Solenoid Control Circuit High..................................................................................... 764 DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low.................................. 766 DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High..................................................... 768 DTC P1702: Internal Control Module Memory Check Sum Error..................................................................................... 770 DTC P1723: Range Select Switch Malfunction.................................................................................................... 770 DTC P1878: Torque Converter Clutch Shudder.................................................................................................... 771 DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance........................................ 772 DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High....................................................... 774 DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low................................................ 776 DTC U0073: Control Module Communication Bus Off............................................................................................... 778 DTC U0100: Lost Communication with ECM / PCM “A”.............................................................................................. 778 Inspection of TCM and Its Circuits............................................................................................................ 778 TCM Power and Ground Circuit Check............................................................................................................ 782 Brake Interlock System Inspection............................................................................................................. 783 Repair Instructions............................................................................................................................... 784 Learning Control Initialization............................................................................................................... 784 A/T Fluid Level Check......................................................................................................................... 784 A/T Fluid Change.............................................................................................................................. 785 Select Lever Components....................................................................................................................... 786 Select Lever Assembly Removal and Installation................................................................................................ 786 Select Lever Knob Installation................................................................................................................ 786 Select Lever Inspection....................................................................................................................... 787 “3” Position Switch Inspection................................................................................................................ 787 Shift Lock Solenoid Inspection................................................................................................................ 787 Shift Lock Solenoid Replacement............................................................................................................... 787 Select Cable Components....................................................................................................................... 788 Select Cable Removal and Installation......................................................................................................... 788 Select Cable Adjustment....................................................................................................................... 788 Key Interlock Cable Removal and Installation.................................................................................................. 789 Transmission Range Sensor Inspection and Adjustment........................................................................................... 791 Output Shaft Speed Sensor (VSS) Removal and Installation...................................................................................... 792 Output Shaft Speed Sensor (VSS) Inspection.................................................................................................... 792 Input Shaft Speed Sensor Removal and Installation............................................................................................. 793 Input Shaft Speed Sensor Inspection........................................................................................................... 793 Transmission Fluid Temperature Sensor Removal and Installation................................................................................ 793 Transmission Fluid Temperature Sensor Inspection.............................................................................................. 794 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation.................................................... 794 Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Inspection.................................................................. 796 Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Solenoid) Removal and Installation........................................ 797 Pressure Control Solenoid Valves Inspection................................................................................................... 798 Transmission Control Module (TCM) Removal and Installation.................................................................................... 799 A/T Relay Inspection.......................................................................................................................... 799 Differential Side Oil Seal Replacement........................................................................................................ 800 A/T Fluid Cooler Hoses Replacement............................................................................................................ 800 Automatic Transaxle Unit Components........................................................................................................... 801 Automatic Transaxle Unit Dismounting and Remounting........................................................................................... 802 Automatic Transaxle Assembly Components....................................................................................................... 804 Automatic Transaxle Unit Disassembly.......................................................................................................... 806 Oil Pump Assembly Components.................................................................................................................. 818 Oil Pump Assembly Disassembly and Reassembly.................................................................................................. 818 Oil Pump Assembly Inspection.................................................................................................................. 819 Direct Clutch Assembly Components............................................................................................................. 821 Direct Clutch Assembly Preliminary Check...................................................................................................... 821 Direct Clutch Assembly Disassembly and Reassembly............................................................................................. 822 Direct Clutch Assembly Inspection............................................................................................................. 824 Forward and Reverse Clutch Assembly Components................................................................................................ 825 Forward and Reverse Clutch Assembly Preliminary Check......................................................................................... 825 Forward and Reverse Clutch Assembly Disassembly and Reassembly................................................................................ 826 Forward and Reverse Clutch Assembly Inspection................................................................................................ 829 2nd Brake Piston Assembly Components.......................................................................................................... 830 2nd Brake Piston Assembly Disassembly and Reassembly.......................................................................................... 830 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components..................................................................... 831 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly..................................................... 832 Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection..................................................................... 833 Countershaft Assembly Components.............................................................................................................. 834 Countershaft Assembly Disassembly and Reassembly.............................................................................................. 834 Valve Body Assembly Components................................................................................................................ 835 Valve Body Assembly Disassembly and Reassembly................................................................................................ 836 Differential Assembly Components.............................................................................................................. 837 Differential Assembly Disassembly and Reassembly.............................................................................................. 838 Differential Assembly Inspection.............................................................................................................. 839 Torque Converter Housing Disassembly and Reassembly........................................................................................... 840 Transaxle Case Disassembly and Reassembly..................................................................................................... 842 Automatic Transaxle Unit Inspection and Adjustment............................................................................................ 843 Automatic Transaxle Unit Assembly............................................................................................................. 846 Specifications.................................................................................................................................... 863 Tightening Torque Specifications.............................................................................................................. 863 Special Tools and Equipment....................................................................................................................... 864 Recommended Service Material.................................................................................................................. 864 Special Tool.................................................................................................................................. 864 Manual Transmission/Transaxle......................................................................................................................... 867 General Description............................................................................................................................... 867 Manual Transaxle Construction................................................................................................................. 867 Diagnostic Information and Procedures............................................................................................................. 871 Manual Transaxle Symptom Diagnosis............................................................................................................ 871 Repair Instructions............................................................................................................................... 871 Manual Transaxle Oil Level Check.............................................................................................................. 871 Manual Transaxle Oil Change................................................................................................................... 872 Differential Side Oil Seal Replacement........................................................................................................ 873 Gear Shift Control Lever and Cable Components................................................................................................. 874 Gear Shift Control Lever and Cable Removal and Installation................................................................................... 875 Gear Select Control Cable Adjustment.......................................................................................................... 875 Back Up Light Switch Removal and Installation................................................................................................. 876 Back Up Light Switch Inspection............................................................................................................... 876 Manual Transaxle Unit Components.............................................................................................................. 877 Manual Transaxle Unit Dismounting and Remounting.............................................................................................. 878 Gear Shift and Select Shaft Assembly Components............................................................................................... 879 Gear Shift and Select Shaft Assembly Removal and Installation................................................................................. 880 Gear Shift and Select Shaft Assembly Disassembly and Reassembly............................................................................... 881 Manual Transaxle Assembly Components.......................................................................................................... 882 Fifth Gear Disassembly and Reassembly......................................................................................................... 883 Manual Transaxle Assembly Disassembly and Reassembly.......................................................................................... 885 Right Case Disassembly and Reassembly......................................................................................................... 890 Left Case Disassembly and Reassembly.......................................................................................................... 891 Input Shaft and Countershaft Components....................................................................................................... 893 Input Shaft Disassembly and Reassembly........................................................................................................ 894 Countershaft Disassembly and Reassembly....................................................................................................... 897 Gear Shift Shaft Components................................................................................................................... 901 5th and Reverse Gear Shift Shafts Disassembly and Reassembly.................................................................................. 901 Gear Shift Shaft and Fork Inspection.......................................................................................................... 901 Differential Components....................................................................................................................... 902 Differential Disassembly and Reassembly....................................................................................................... 902 Specifications.................................................................................................................................... 904 Tightening Torque Specifications.............................................................................................................. 904 Special Tools and Equipment....................................................................................................................... 905 Recommended Service Material.................................................................................................................. 905 Special Tool.................................................................................................................................. 905 Clutch................................................................................................................................................ 908 General Description............................................................................................................................... 908 Clutch (Hydraulic Type) Construction.......................................................................................................... 908 Diagnostic Information and Procedures............................................................................................................. 909 Clutch System Symptom Diagnosis............................................................................................................... 909 Repair Instructions............................................................................................................................... 910 Clutch Pedal Inspection....................................................................................................................... 910 Clutch Fluid Level Inspection................................................................................................................. 910 Air Bleeding of Clutch System................................................................................................................. 910 Clutch Fluid Pipe and Hose Components......................................................................................................... 911 Clutch Fluid Pipe Removal and Installation.................................................................................................... 911 Clutch Fluid Pipe Inspection.................................................................................................................. 911 Clutch Master Cylinder Removal and Installation............................................................................................... 912 Clutch Operating Cylinder Assembly Removal and Installation................................................................................... 912 Clutch Operating Cylinder Assembly Inspection................................................................................................. 913 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................. 913 Clutch Cover, Clutch Disc and Flywheel Removal and Installation............................................................................... 914 Clutch Cover, Clutch Disc and Flywheel Inspection............................................................................................. 915 Specifications.................................................................................................................................... 916 Tightening Torque Specifications.............................................................................................................. 916 Special Tools and Equipment....................................................................................................................... 917 Recommended Service Material.................................................................................................................. 917 Special Tool.................................................................................................................................. 917 Steering.................................................................................................................................................. 919 Precautions........................................................................................................................................... 921 Precautions....................................................................................................................................... 921 Precautions on Steering....................................................................................................................... 921 Steering General Diagnosis............................................................................................................................ 922 Precautions....................................................................................................................................... 922 Precautions for Steering Diagnosis............................................................................................................ 922 Diagnostic Information and Procedures............................................................................................................. 922 Steering Symptom Diagnosis.................................................................................................................... 922 Steering System Inspection.................................................................................................................... 923 Steering Wheel and Column............................................................................................................................. 924 Precautions....................................................................................................................................... 924 Service Precautions of Steering Wheel and Column.............................................................................................. 924 General Description............................................................................................................................... 924 Steering Wheel and Column Construction........................................................................................................ 924 Diagnostic Information and Procedures............................................................................................................. 925 Checking Steering Column for Accident Damage.................................................................................................. 925 Repair Instructions............................................................................................................................... 926 Steering Wheel and Column Components.......................................................................................................... 926 Steering Wheel Removal and Installation....................................................................................................... 927 Contact Coil Cable Assembly Removal and Installation.......................................................................................... 928 Centering Contact Coil Cable Assembly......................................................................................................... 929 Contact Coil Cable Assembly Inspection........................................................................................................ 929 Steering Angle Sensor Removal and Installation (ESP‚ model)................................................................................... 929 Steering Angle Sensor Inspection (ESP‚ model)................................................................................................. 930 Steering Column Removal and Installation...................................................................................................... 930 Steering Column Inspection.................................................................................................................... 931 Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)......................................................... 932 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................. 932 Steering Lower Shaft Removal and Installation................................................................................................. 933 Specifications.................................................................................................................................... 934 Tightening Torque Specifications.............................................................................................................. 934 Special Tools and Equipment....................................................................................................................... 934 Special Tool.................................................................................................................................. 934 Power Assisted Steering System........................................................................................................................ 935 Precautions....................................................................................................................................... 935 P/S System Note............................................................................................................................... 935 Precautions in Diagnosing Troubles............................................................................................................ 935 General Description............................................................................................................................... 936 P/S System Description........................................................................................................................ 936 EPS Diagnosis General Description............................................................................................................. 937 On-Board Diagnostic System Description........................................................................................................ 937 Schematic and Routing Diagram..................................................................................................................... 938 EPS System Wiring Circuit Diagram............................................................................................................. 938 Diagnostic Information and Procedures............................................................................................................. 939 EPS System Check.............................................................................................................................. 939 “EPS” Warning Light Check..................................................................................................................... 942 DTC Check..................................................................................................................................... 942 DTC Clearance................................................................................................................................. 943 DTC Table..................................................................................................................................... 943 Visual Inspection............................................................................................................................. 945 Scan Tool Data................................................................................................................................ 946 P/S System Symptom Diagnosis.................................................................................................................. 947 DLC and Its Communication Check (No communication to P/S Control Module)...................................................................... 948 “EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts...................................................... 950 “EPS” Warning Light Remains ON Steady after Engine Starts..................................................................................... 952 DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure...................................................................................... 953 DTC C1116: Steering Torque Sensor Power Supply Circuit........................................................................................ 955 DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure............................................................................... 956 DTC C1122: Engine Speed Signal................................................................................................................ 958 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure...................................................................................... 960 DTC C1153: P/S Control Module Power Supply Circuit............................................................................................ 961 DTC C1155: P/S Control Module Internal Failure................................................................................................ 962 P/S Control Module Power Supply and Ground Circuit Check...................................................................................... 963 Inspection of P/S Control Module and Its Circuits............................................................................................. 964 Steering Wheel Play Check..................................................................................................................... 968 Steering Force Check.......................................................................................................................... 968 Repair Instructions............................................................................................................................... 969 Steering Gear Case Assembly Components........................................................................................................ 969 Tie-Rod End Boot On-Vehicle Inspection........................................................................................................ 970 Tie-Rod End Removal and Installation.......................................................................................................... 970 Tie-Rod End Initial Position Setting.......................................................................................................... 971 Tie-Rod End Inspection........................................................................................................................ 971 Steering Shaft Joint On-Vehicle Inspection.................................................................................................... 971 Steering Gear Case Assembly Removal and Installation.......................................................................................... 972 Steering Rack Boot Inspection................................................................................................................. 973 Tie-Rod / Rack Boot Removal and Installation.................................................................................................. 973 Steering Rack Plunger Removal and Installation................................................................................................ 974 Steering Rack Plunger Inspection.............................................................................................................. 975 P/S Control Module Removal and Installation................................................................................................... 975 Torque Sensor and Its Circuit Inspection...................................................................................................... 976 P/S Motor and Its Circuit Inspection.......................................................................................................... 977 Specifications.................................................................................................................................... 978 Tightening Torque Specifications.............................................................................................................. 978 Special Tools and Equipment....................................................................................................................... 978 Recommended Service Material.................................................................................................................. 978 Special Tool.................................................................................................................................. 978 HVAC...................................................................................................................................................... 979 Precautions........................................................................................................................................... 982 Precautions....................................................................................................................................... 982 Precautions on HVAC........................................................................................................................... 982 Heater and Ventilation................................................................................................................................ 983 Schematic and Routing Diagram..................................................................................................................... 983 Heater and Ventilation Diagram................................................................................................................ 983 Heater and Ventilation Wiring Circuit Diagram................................................................................................. 984 Component Location................................................................................................................................ 984 Electronic Control System Components Location................................................................................................. 984 Diagnostic Information and Procedures............................................................................................................. 985 Heater and Ventilation Symptom Diagnosis...................................................................................................... 985 Repair Instructions............................................................................................................................... 986 HVAC Unit Components.......................................................................................................................... 986 HVAC Unit Removal and Installation (Non-A/C).................................................................................................. 986 Blower Motor Removal and Installation......................................................................................................... 986 Blower Motor Inspection....................................................................................................................... 986 Blower Motor Resistor Removal and Installation................................................................................................ 987 Blower Motor Resistor Inspection.............................................................................................................. 987 Blower Motor Relay Inspection................................................................................................................. 988 HVAC Control Unit Components.................................................................................................................. 988 HVAC Control Unit Removal and Installation.................................................................................................... 989 Blower Speed Selector Inspection.............................................................................................................. 991 Air Intake Selector Inspection................................................................................................................ 991 Air Intake Control Actuator Removal and Installation.......................................................................................... 991 Air Intake Control Actuator Inspection........................................................................................................ 992 Center Ventilation Louver Removal and Installation............................................................................................ 993 Side Ventilation Louver Removal and Installation.............................................................................................. 993 Rear Duct Removal and Installation (If Equipped).............................................................................................. 994 HVAC Air Filter Removal and Installation (If Equipped)........................................................................................ 994 HVAC Air Filter Inspection (If Equipped)...................................................................................................... 994 Air Conditioning System............................................................................................................................... 995 Manual Type....................................................................................................................................... 995 Precautions................................................................................................................................... 995 A/C System Caution........................................................................................................................ 995 Precautions on Servicing A/C System....................................................................................................... 995 General Description........................................................................................................................... 996 Sub-Cool A/C System Description........................................................................................................... 996 A/C Operation Description at ECM.......................................................................................................... 997 Schematic and Routing Diagram................................................................................................................. 998 A/C System Air Flow Diagram............................................................................................................... 998 A/C System Wiring Diagram................................................................................................................. 999 Manual A/C Electronic Input Output Diagram................................................................................................1000 Component Location............................................................................................................................1000 A/C System Major Components Location......................................................................................................1000 Electronic Control System Components Location.............................................................................................1001 Diagnostic Information and Procedures.........................................................................................................1002 A/C System Performance Inspection.........................................................................................................1002 Trouble Diagnosis for Abnormal Pressure...................................................................................................1005 A/C System Inspection at ECM..............................................................................................................1006 A/C System Symptom Diagnosis..............................................................................................................1007 Abnormal Noise Symptom Diagnosis of A/C System............................................................................................1009 Repair Instructions...........................................................................................................................1011 Operation Procedure for Refrigerant Charge................................................................................................1011 Condenser Cooling Fan Removal and Installation............................................................................................1016 Condenser Cooling Fan Inspection..........................................................................................................1017 Condenser Assembly On-Vehicle Inspection..................................................................................................1017 Condenser Assembly Removal and Installation...............................................................................................1017 Desiccant Removal and Installation........................................................................................................1018 HVAC Unit Components......................................................................................................................1019 HVAC Unit Removal and Installation........................................................................................................1020 Evaporator Inspection.....................................................................................................................1021 Evaporator Temperature Sensor Removal and Installation....................................................................................1021 Evaporator Temperature Sensor Inspection..................................................................................................1022 Expansion Valve Removal and Installation..................................................................................................1022 Expansion Valve Inspection................................................................................................................1022 A/C Refrigerant Pressure Sensor and Its Circuit Inspection................................................................................1023 A/C Refrigerant Pressure Sensor Removal and Installation..................................................................................1023 A/C Switch Inspection.....................................................................................................................1023 A/C System Relay Inspection...............................................................................................................1024 Compressor Drive Belt Inspection and Adjustment...........................................................................................1024 Compressor Drive Belt Removal and Installation............................................................................................1025 Compressor Assembly Removal and Installation..............................................................................................1025 Compressor Assembly Components............................................................................................................1026 Magnet Clutch Inspection..................................................................................................................1026 Magnet Clutch Removal and Installation....................................................................................................1027 Thermal Switch Inspection.................................................................................................................1029 Thermal Switch Removal and Installation...................................................................................................1029 Relief Valve Inspection...................................................................................................................1029 Relief valve Removal and Installation.....................................................................................................1029 Specifications................................................................................................................................1030 Tightening Torque Specifications..........................................................................................................1030 Special Tools and Equipment...................................................................................................................1031 Recommended Service Material..............................................................................................................1031 Special Tool..............................................................................................................................1031 Automatic Type....................................................................................................................................1032 Precautions...................................................................................................................................1032 A/C System Caution........................................................................................................................1032 Precautions in Diagnosing Trouble.........................................................................................................1032 Precautions on Servicing A/C System.......................................................................................................1032 General Description...........................................................................................................................1032 Auto A/C System Description...............................................................................................................1032 HVAC Control Description..................................................................................................................1033 Sub-Cool A/C System Description...........................................................................................................1033 On-Board Diagnostic System Description....................................................................................................1034 Schematic and Routing Diagram.................................................................................................................1034 A/C System Air Flow Diagram...............................................................................................................1034 A/C System Wiring Diagram.................................................................................................................1035 Auto A/C Electronic Control Input / Output Diagram........................................................................................1036 Component Location............................................................................................................................1036 A/C System Major Components Location......................................................................................................1036 Electronic Control System Components Location.............................................................................................1037 Diagnostic Information and Procedures.........................................................................................................1038 Air Conditioning System Check.............................................................................................................1038 A/C System Symptom Diagnosis..............................................................................................................1040 Abnormal Noise Symptom Diagnosis of A/C System............................................................................................1042 DTC Check.................................................................................................................................1042 DTC Clearance.............................................................................................................................1043 DTC Table.................................................................................................................................1044 Fail-Safe Table...........................................................................................................................1046 Scan Tool Data............................................................................................................................1048 Visual Inspection.........................................................................................................................1049 DTC B1502: Inside Air Temperature Sensor Circuit Malfunction..............................................................................1050 DTC B1503: Evaporator Temperature Sensor Circuit Malfunction..............................................................................1051 DTC B1504: Sunload Sensor Circuit Malfunction.............................................................................................1052 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction..................................................1054 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction.....................................................1055 DTC B1513: Temperature Control Actuator (Motor) and/or Its Circuit Malfunction............................................................1057 DTC B1514: Air Flow Control Actuator (Motor) and/or Its Circuit Malfunction...............................................................1058 DTC B1520 / B1521 / B1522: Temperature / Blower Speed / Air Flow Selector Malfunction.....................................................1059 DTC B1541: Back-Up Power Supply Circuit Malfunction.......................................................................................1060 DTC B1546: A/C Refrigerant Pressure Malfunction...........................................................................................1061 DTC B1551: Serial Communication Circuit Malfunction.......................................................................................1062 DTC B1552: HVAC Control Module Check Sum Error............................................................................................1063 DTC B1553: CAN Communication Circuit Malfunction..........................................................................................1063 DTC B1557: VSS Signal Failure.............................................................................................................1064 DTC B1561: ECT Signal Failure.............................................................................................................1064 DTC B1562: Outside Air Temperature Signal Failure.........................................................................................1065 DTC B1563: A/C Refrigerant Pressure Signal Failure........................................................................................1065 DTC B1570: Engine Type Signal Failure.....................................................................................................1066 DTC B1571: Combination Meter Spec Signal Failure..........................................................................................1066 Inspection of HVAC Control Module and Its Circuit.........................................................................................1067 A/C System Inspection at ECM..............................................................................................................1070 Repair Instructions...........................................................................................................................1070 Operation Procedure for Refrigerant Charge................................................................................................1070 HVAC Unit Components......................................................................................................................1071 HVAC Unit Removal and Installation........................................................................................................1072 Temperature Control Actuator Removal and Installation.....................................................................................1072 Temperature Control Actuator and Its Circuit Inspection...................................................................................1072 Air Flow Control Actuator Removal and Installation........................................................................................1074 Air Flow Control Actuator and Its Circuit Inspection......................................................................................1074 Air Intake Actuator Removal and Installation..............................................................................................1075 Air Intake Actuator Inspection............................................................................................................1075 Actuator Linkage Inspection...............................................................................................................1075 Blower Motor Controller Removal and Installation..........................................................................................1075 Blower Motor Controller Inspection........................................................................................................1076 HVAC Control Module Removal and Installation..............................................................................................1076 Sunload Sensor Removal and Installation...................................................................................................1076 Sunload Sensor Inspection.................................................................................................................1077 Outside Air Temperature Sensor Removal and Installation...................................................................................1077 Outside Air Temperature Sensor Inspection.................................................................................................1077 Inside Air Temperature Sensor Removal and Installation....................................................................................1077 Inside Air Temperature Sensor Inspection..................................................................................................1077 Condenser Cooling Fan Relay Inspection....................................................................................................1078 Condenser Cooling Fan Removal and Installation............................................................................................1078 Condenser Cooling Fan Inspection..........................................................................................................1078 Condenser Assembly On-Vehicle Inspection..................................................................................................1078 Condenser Assembly Removal and Installation...............................................................................................1078 Evaporator Inspection.....................................................................................................................1078 Evaporator Temperature Sensor Removal and Installation....................................................................................1078 Evaporator Temperature Sensor Inspection..................................................................................................1078 Expansion Valve Removal and Installation..................................................................................................1078 Expansion Valve Inspection................................................................................................................1078 A/C Refrigerant Pressure Sensor and Its Circuit Inspection................................................................................1078 A/C Refrigerant Pressure Sensor Removal and Installation..................................................................................1078 Compressor Relay Inspection...............................................................................................................1078 Compressor Drive Belt Inspection and Adjustment...........................................................................................1078 Compressor Drive Belt Removal and Installation............................................................................................1078 Compressor Assembly Removal and Installation..............................................................................................1078 Compressor Assembly Components............................................................................................................1078 Magnet Clutch Removal and Installation....................................................................................................1078 Magnet Clutch Inspection..................................................................................................................1078 Thermal Switch Inspection.................................................................................................................1078 Thermal Switch Removal and Installation...................................................................................................1078 Relief Valve Inspection...................................................................................................................1078 Special Tools and Equipment...................................................................................................................1079 Recommended Service Material..............................................................................................................1079 Special Tool..............................................................................................................................1079 Restraint.................................................................................................................................................1081 Precautions...........................................................................................................................................1083 Precautions.......................................................................................................................................1083 Precautions on Restraint......................................................................................................................1083 Seat Belts............................................................................................................................................1084 Precautions.......................................................................................................................................1084 Precautions on Service and Diagnosis of Seat Belt.............................................................................................1084 General Description...............................................................................................................................1085 Seat Belt Construction........................................................................................................................1085 Diagnostic Information and Procedures.............................................................................................................1087 Repair and Inspection Required after Accident.................................................................................................1087 Repair Instructions...............................................................................................................................1088 Front Seat Belt Components....................................................................................................................1088 Front Seat Belt Removal and Installation......................................................................................................1089 Front Seat Belt Inspection....................................................................................................................1090 Rear Seat Belt Components.....................................................................................................................1091 Rear Seat Belt Removal and Installation.......................................................................................................1093 Rear Seat Belt Inspection.....................................................................................................................1093 Specifications....................................................................................................................................1093 Tightening Torque Specifications..............................................................................................................1093 Air Bag System........................................................................................................................................1094 Precautions.......................................................................................................................................1094 Precautions on Service and Diagnosis of Air Bag System........................................................................................1094 Precautions on Handling and Storage of Air Bag System Components..............................................................................1094 Precautions on Disposal of Air Bag and Seat Belt Pretensioner.................................................................................1098 General Description...............................................................................................................................1098 Air Bag System Construction...................................................................................................................1098 Air Bag System Input / Output Table...........................................................................................................1099 Schematic and Routing Diagram.....................................................................................................................1100 Air Bag System Wiring Circuit Diagram.........................................................................................................1100 Air Bag System Input / Output Diagram.........................................................................................................1102 Component Location................................................................................................................................1103 Air Bag System Components, Wiring and Connectors Location.....................................................................................1103 Diagnostic Information and Procedures.............................................................................................................1104 Air Bag Diagnostic System Check...............................................................................................................1104 Air Bag Diagnostic System Check Flow..........................................................................................................1105 DTC Table.....................................................................................................................................1106 DTC Check.....................................................................................................................................1110 DTC Clearance.................................................................................................................................1110 Scan Tool Data................................................................................................................................1110 “AIR BAG” Warning Light Comes ON Steady.......................................................................................................1111 “AIR BAG” Warning Light Does Not Come ON......................................................................................................1114 Serial Data Link Circuit Check................................................................................................................1115 DTC B1013: SDM Internal Failure...............................................................................................................1117 DTC B1014: “AIR BAG” Warning Light Circuit....................................................................................................1118 DTC B1016: Power Supply Voltage too High......................................................................................................1118 DTC B1017: Power Supply Voltage too Low.......................................................................................................1119 DTC B1021: Front Air Bag Deployment Record....................................................................................................1120 DTC B1024 / B1025: Side Air-Bag Deployment Record.............................................................................................1121 DTC B1026: Seat Belt Pretensioner Activation Record...........................................................................................1121 DTC B1027: Number of Deployment Times Exceeded Limit..........................................................................................1122 DTC B1031: Driver Air Bag Circuit High Resistance.............................................................................................1123 DTC B1032: Driver Air Bag Circuit Low Resistance..............................................................................................1125 DTC B1033: Driver Air Bag Circuit Shorted to Ground...........................................................................................1127 DTC B1034: Driver Air Bag Circuit Shorted to Power Supply.....................................................................................1129 DTC B1041: Passenger Air Bag Circuit High Resistance..........................................................................................1132 DTC B1042: Passenger Air Bag Circuit Low Resistance...........................................................................................1135 DTC B1043: Passenger Air Bag Circuit Shorted to Ground........................................................................................1137 DTC B1044: Passenger Air Bag Circuit Shorted to Power Supply..................................................................................1138 DTC B1051 / B1055: Seat Belt Pretensioner Circuit High Resistance.............................................................................1140 DTC B1052 / B1056: Seat Belt Pretensioner Circuit Low Resistance..............................................................................1143 DTC B1053 / B1057: Seat Belt Pretensioner Shorted to Ground...................................................................................1144 DTC B1054 / B1058: Seat Belt Pretensioner Circuit Shorted to Power Supply.....................................................................1146 DTC B1061 / B1065: Side-Air Bag Circuit High Resistance.......................................................................................1147 DTC B1062 / B1066: Side-Air Bag Circuit Low Resistance........................................................................................1151 DTC B1063 / B1067: Side-Air Bag Circuit Shorted to Ground.....................................................................................1153 DTC B1064 / B1068: Side-Air Bag Circuit Shorted to Power Supply...............................................................................1156 DTC B1071: Driver Forward Impact-Sensor Communication Data Inconsistent.......................................................................1158 DTC B1072: Driver Forward Impact-Sensor Communication Data Invalid............................................................................1158 DTC B1073: Driver Forward Impact-Sensor Circuit Shorted to Ground.............................................................................1159 DTC B1074: Driver Forward Impact-Sensor Circuit Open..........................................................................................1160 DTC B1081 / B1091: Side Impact-Sensor No Response.............................................................................................1162 DTC B1082 / B1092: Side Impact-Sensor Communication DATA Invalid..............................................................................1162 DTC B1083 / B1093: Side Impact-Sensor Circuit Shorted to Ground...............................................................................1163 DTC B1084 / B1094: Side Impact-Sensor Circuit Open............................................................................................1165 DTC B1085 / B1095: Side Impact-Sensor Communication DATA Inconsistent.........................................................................1166 DTC B1361 / B1365: Curtain-Air Bag Circuit High Resistance....................................................................................1167 DTC B1362 / B1366: Curtain-Air Bag Circuit Low Resistance.....................................................................................1171 DTC B1363 / B1367: Curtain-Air Bag Circuit Shorted to Ground..................................................................................1174 DTC B1364 / B1368: Curtain-Air Bag Circuit Shorted to Power Supply............................................................................1176 SDM Power Supply and Ground Circuit Check.....................................................................................................1178 Contact Coil Cable and Its Circuit Check......................................................................................................1180 Inspection of Intermittent and Poor Connections...............................................................................................1183 Repair and Inspection Required after Accident.................................................................................................1184 Repair Instructions...............................................................................................................................1187 Disabling Air Bag System......................................................................................................................1187 Enabling Air Bag System.......................................................................................................................1188 SDM Removal and Installation..................................................................................................................1188 SDM Inspection................................................................................................................................1190 Driver Air Bag (Inflator) Module Removal and Installation.....................................................................................1190 Driver Air Bag (Inflator) Module Inspection...................................................................................................1191 Passenger Air Bag (Inflator) Module Removal and Installation..................................................................................1191 Passenger Air Bag (Inflator) Module Inspection................................................................................................1193 Side-Air Bag (Inflator) Module Removal and Installation.......................................................................................1194 Side-Air Bag (Inflator) Inspection............................................................................................................1196 Side Curtain-Air Bag (Inflator) Module Removal and Installation...............................................................................1196 Side Curtain-Air Bag (Inflator) Module Inspection.............................................................................................1198 Forward Impact-Sensor Removal and Installation................................................................................................1199 Forward Impact-Sensor Inspection..............................................................................................................1200 Side Impact-Sensor Removal and Installation...................................................................................................1200 Side Impact-Sensor Inspection.................................................................................................................1201 Passenger Air Bag (Inflator) Module Repair Harness Installation...............................................................................1201 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal.................................................................................1202 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal..............................................................1213 Specifications....................................................................................................................................1214 Tightening Torque Specifications..............................................................................................................1214 Special Tools and Equipment.......................................................................................................................1214 Use of Special Tools..........................................................................................................................1214 Special Tool..................................................................................................................................1216 Body, Cab and Accessories.................................................................................................................................1217 Precautions...........................................................................................................................................1223 Precautions.......................................................................................................................................1223 Precautions on Body, Cab and Accessories......................................................................................................1223 Precautions for Body Service..................................................................................................................1223 Fastener Caution for Body Service.............................................................................................................1223 Wiring Systems........................................................................................................................................1224 Precautions.......................................................................................................................................1224 Cautions in Body Electrical System Servicing..................................................................................................1224 General Description...............................................................................................................................1224 Abbreviations.................................................................................................................................1224 Wire / Connector Color Symbols................................................................................................................1224 Symbols and Marks.............................................................................................................................1225 How to Read Connector Layout Diagram..........................................................................................................1227 How to Read Connector Codes and Terminal Nos..................................................................................................1228 How to Read Ground Point......................................................................................................................1231 How to Read Power Supply Diagram..............................................................................................................1232 How to Read System Circuit Diagram............................................................................................................1232 Connector Layout Diagram..........................................................................................................................1234 Connector Layout Diagram......................................................................................................................1234 Engine Compartment............................................................................................................................1234 Instrument Panel..............................................................................................................................1245 Door, Roof....................................................................................................................................1251 Floor.........................................................................................................................................1255 Rear..........................................................................................................................................1265 Ground Point......................................................................................................................................1266 Ground (earth) Point..........................................................................................................................1266 Power Supply Diagram..............................................................................................................................1267 Power Supply Diagram..........................................................................................................................1267 Fuses and the Protected Parts.................................................................................................................1269 Fuses in Main Fuse Box........................................................................................................................1269 Individual Circuit Fuse Box No. 1.............................................................................................................1270 Individual Circuit Fuse Box No. 2 (In J/B (Except Taiwan))....................................................................................1271 Individual Circuit Fuse Box No. 2 (In J/B (Taiwan))...........................................................................................1273 Individual Circuit Fuse Box No.3 (Sedan)......................................................................................................1275 Junction Block (J/B) Connector / Fuse Layout..................................................................................................1276 Junction Block Inner Circuit (Overview (Except Taiwan)).......................................................................................1277 Junction Block Inner Circuit (Detail (Except Taiwan)).........................................................................................1279 Junction Block Inner Circuit (Overview (Taiwan))..............................................................................................1284 Junction Block Inner Circuit (Detail (Taiwan))................................................................................................1286 System Circuit Diagram............................................................................................................................1291 System Circuit Diagram........................................................................................................................1291 A-1 Cranking System Circuit Diagram...........................................................................................................1293 A-2 Charging System Circuit Diagram...........................................................................................................1294 A-3 Ignition System Circuit Diagram (M15A engine, M16A engine)................................................................................1295 A-3 Ignition System Circuit Diagram (J20A engine).............................................................................................1296 A-4 Cooling System Circuit Diagram (M15A engine, M16A engine).................................................................................1297 A-4 Cooling System Circuit Diagram (J20A engine)..............................................................................................1298 A-5 Engine and A/C Control System Circuit Diagram (M15A engine)...............................................................................1299 A-5 Engine and A/C Control System Circuit Diagram (M16A engine)...............................................................................1303 A-5 Engine and A/C Control System Circuit Diagram (J20A engine)...............................................................................1307 A-6 A/T Control System Circuit Diagram........................................................................................................1311 A-7 Immobilizer System Circuit Diagram........................................................................................................1313 A-8 Body Control System Circuit Diagram (Except Taiwan).......................................................................................1314 A-8 Body Control System Circuit Diagram (Taiwan)..............................................................................................1318 A-10 4WD Control System (Except Taiwan).......................................................................................................1322 B-1 Windshield Wiper and Washer Circuit Diagram...............................................................................................1323 B-2 Rear Wiper and Washer Circuit Diagram (Except Taiwan).....................................................................................1324 B-2 Rear Wiper and Washer Circuit Diagram (Taiwan)............................................................................................1325 B-3 Rear Defogger Circuit Diagram (Hatchback (Except Taiwan)).................................................................................1326 B-3 Rear Defogger Circuit Diagram (Hatchback (Taiwan))........................................................................................1327 B-3 Rear Defogger Circuit Diagram (Sedan).....................................................................................................1328 B-4 Power Window Circuit Diagram..............................................................................................................1329 B-5 Power Door Lock Circuit Diagram (Except Taiwan)...........................................................................................1331 B-5 Power Door Lock Circuit Diagram (Taiwan)..................................................................................................1333 B-6 Power Mirror Circuit Diagram (Hatchback (Except Taiwan))..................................................................................1335 B-6 Power Mirror Circuit Diagram (Hatchback (Taiwan)).........................................................................................1336 B-6 Power Mirror Circuit Diagram (Sedan (Except Taiwan))......................................................................................1337 B-6 Power Mirror Circuit Diagram (Sedan (Taiwan)).............................................................................................1338 B-7 Horn Circuit Diagram......................................................................................................................1339 B-8 Seat Heater Circuit Diagram...............................................................................................................1340 B-9 Keyless Start System Circuit Diagram......................................................................................................1341 C-1 Combination Meter Circuit Diagram (Meter).................................................................................................1342 C-2 Combination Meter Circuit Diagram (Indicator).............................................................................................1343 C-3 Combination Meter Circuit Diagram (Warning Light).........................................................................................1344 D-1 Headlight System Circuit Diagram (Except Taiwan)..........................................................................................1346 D-1 Headlight System Circuit Diagram (Taiwan).................................................................................................1348 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Hatchback (Except Taiwan)).................................................1349 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Sedan (Except Taiwan)).....................................................1350 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Hatchback (Taiwan))........................................................1351 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Sedan (Taiwan))............................................................1352 D-3 Front Fog Light System Circuit Diagram (Except Taiwan)....................................................................................1353 D-3 Front Fog Light System Circuit Diagram (Taiwan)...........................................................................................1354 D-4 Illumination Light System Circuit Diagram (Except Taiwan).................................................................................1355 D-4 Illumination Light System Circuit Diagram (Taiwan)........................................................................................1356 D-5 Interior Light System Circuit Diagram (Hatchback (Except Taiwan)).........................................................................1357 D-5 Interior Light System Circuit Diagram (Hatchback (Taiwan))................................................................................1358 D-5 Interior Light System Circuit Diagram (Sedan (Except Taiwan)).............................................................................1359 D-5 Interior Light System Circuit Diagram (Sedan (Taiwan))....................................................................................1360 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Hatchback (Except Taiwan))...................................................1361 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Sedan (Except Taiwan)).......................................................1363 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Hatchback (Taiwan))..........................................................1365 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Sedan (Taiwan))..............................................................1367 D-7 Brake Light System Circuit Diagram (Hatchback)............................................................................................1369 D-7 Brake Light System Circuit Diagram (Sedan)................................................................................................1370 D-8 Back-Up Light System Circuit Diagram (Hatchback)..........................................................................................1371 D-8 Back-Up Light System Circuit Diagram (Sedan)..............................................................................................1372 D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling)..........................................................................1373 D-10 Rear Fog Light Circuit Diagram (Hatchback)...............................................................................................1374 D-10 Rear Fog Light Circuit Diagram (Sedan)...................................................................................................1375 E-1 Heater System Circuit Diagram.............................................................................................................1376 E-2 Auto A/C System Circuit Diagram...........................................................................................................1378 F-1 Air-Bag System Circuit Diagram (4ch)......................................................................................................1380 F-1 Air-Bag System Circuit Diagram (8ch)......................................................................................................1381 F-2 Anti-Lock Brake System Circuit Diagram....................................................................................................1383 F-3 Electronic Stability Program System Circuit Diagram.......................................................................................1385 F-4 Power Steering System Circuit Diagram.....................................................................................................1387 G-1 Audio System Circuit Diagram..............................................................................................................1389 G-2 Multi Information Display / Accessory Socket System Circuit Diagram.......................................................................1391 G-4 Navigation System Circuit Diagram.........................................................................................................1392 List of Connector.................................................................................................................................1394 List of Connectors............................................................................................................................1394 C Connector...................................................................................................................................1394 E Connector...................................................................................................................................1395 G Connector...................................................................................................................................1397 J Connector...................................................................................................................................1399 K Connector...................................................................................................................................1400 L Connector...................................................................................................................................1400 M Connector (Sedan)...........................................................................................................................1403 O Connector (Hatchback).......................................................................................................................1403 Q Connector (8ch).............................................................................................................................1404 R Connector...................................................................................................................................1404 S Connector...................................................................................................................................1404 Lighting Systems......................................................................................................................................1405 Precautions.......................................................................................................................................1405 Precautions for Discharge Headlight Service (If Equipped).....................................................................................1405 Precautions in Diagnosing Troubles (Headlight Auto Leveling System)...........................................................................1405 General Description...............................................................................................................................1405 Discharge Headlight Description (If Equipped).................................................................................................1405 Headlight Auto Leveling System Description (If Equipped)......................................................................................1406 Auto-On Headlight System Description (If Equipped)............................................................................................1408 Schematic and Routing Diagram.....................................................................................................................1409 Headlight Auto Leveling System Wiring Circuit Diagram.........................................................................................1409 Component Location................................................................................................................................1409 Lighting System Components Location...........................................................................................................1409 Interior Light System Location................................................................................................................1411 Diagnostic Information and Procedures.............................................................................................................1411 Self-Diagnosis Function for Headlight Auto Leveling System....................................................................................1411 Headlight Leveling Warning Light Check........................................................................................................1412 Headlight Symptom Diagnosis (Discharge Headlight Model).......................................................................................1412 Headlight Symptom diagnosis (Other than Discharge Headlight Model)............................................................................1413 Auto-On Headlight System Symptom Diagnosis (If Equipped)......................................................................................1413 DRL System Symptom Diagnosis (If Equipped)....................................................................................................1414 Headlight Auto Leveling System Symptom Diagnosis (If Equipped)................................................................................1414 Headlight Manual Leveling System Symptom Diagnosis (If Equipped)..............................................................................1414 Turn Signal and Hazard Warning Light Symptom Diagnosis........................................................................................1415 Clearance, Tail and License Plate Light Symptom Diagnosis.....................................................................................1415 Back-Up Light Symptom Diagnosis...............................................................................................................1416 Brake Light Symptom Diagnosis.................................................................................................................1416 Front Fog Light Symptom Diagnosis (If Equipped)...............................................................................................1416 Rear Fog Light Symptom Diagnosis (If Equipped)................................................................................................1416 Illumination Cancel System Symptom Diagnosis (If Equipped)....................................................................................1417 Interior Light Symptom Diagnosis..............................................................................................................1417 DRL Operation Inspection (If Equipped)........................................................................................................1417 Inspection of DRL Controller and Its Circuits (If Equipped)...................................................................................1418 Auto-On Headlight Operation Inspection (If Equipped)..........................................................................................1419 Inspection of Auto-On Headlight Controller and Its Circuit (If Equipped)......................................................................1419 Inspection of Headlight Leveling Control Module and Its Circuit (Headlight Auto Leveling System)..............................................1420 Repair Instructions...............................................................................................................................1422 Headlight Housing Removal and Installation....................................................................................................1422 Headlight Bulb Replacement (Discharge Headlight Model)........................................................................................1423 Ballast Removal and Installation (Discharge Headlight Model)..................................................................................1423 Igniter Removal and Installation (Discharge Headlight Model)..................................................................................1424 Headlight Aiming Adjustment with Screen.......................................................................................................1424 Headlight Switch (in Lighting Switch) Removal and Installation................................................................................1426 Headlight Switch (in Lighting Switch) Inspection..............................................................................................1426 Hazard Warning Switch Removal and Installation................................................................................................1427 Hazard Warning Switch Inspection..............................................................................................................1427 Brake Light Switch Inspection.................................................................................................................1427 Turn Signal Light Switch (in Lighting Switch) Removal and Installation........................................................................1428 Turn Signal Light Switch (in Lighting Switch) Inspection......................................................................................1428 Turn Signal and Hazard Warning Relay Removal and Installation.................................................................................1428 Turn Signal and Hazard Warning Relay Inspection...............................................................................................1429 License Light Assembly Removal and Installation (Hatchback)...................................................................................1429 License Light Removal and Installation (Sedan)................................................................................................1430 Front Fog Light Assembly Removal and Installation (If Equipped)...............................................................................1430 Front Fog Light Switch Inspection (If Equipped)...............................................................................................1431 Front Fog Light Aiming Adjustment with Screen (If Equipped)...................................................................................1431 Rear Fog Light Switch Inspection (If Equipped)................................................................................................1432 Headlight Manual Levering Switch Inspection (If Equipped).....................................................................................1433 Headlight Leveling Actuator Inspection (If Equipped)..........................................................................................1433 Height Sensor Removal and Installation (If Equipped)..........................................................................................1434 Height Sensor and Its Circuit Inspection (If Equipped)........................................................................................1435 Headlight Leveling Control Module Removal and Installation (If Equipped)......................................................................1435 Initialization of Headlight Auto Leveling System..............................................................................................1435 Auto-On Headlight Sensor Inspection (If Equipped).............................................................................................1436 Illumination Cancel Switch Inspection (If Equipped)...........................................................................................1437 Tail Light Relay, Headlight Relay, Front Fog Light Relay Inspection (If Equipped).............................................................1437 Specifications....................................................................................................................................1438 Tightening Torque Specifications..............................................................................................................1438 Instrumentation / Driver Info. / Horn.................................................................................................................1439 Precautions.......................................................................................................................................1439 Precautions in Diagnosing Troubles for Combination Meter......................................................................................1439 General Description...............................................................................................................................1439 CAN Communication System Description..........................................................................................................1439 Auto Volume Control System Description (If Equipped)..........................................................................................1441 Schematic and Routing Diagram.....................................................................................................................1442 Combination Meter Circuit Diagram.............................................................................................................1442 Component Location................................................................................................................................1444 Audio System Component Location...............................................................................................................1444 Diagnostic Information and Procedures.............................................................................................................1445 Speedometer and VSS Symptom Diagnosis.........................................................................................................1445 Tachometer Symptom Diagnosis..................................................................................................................1445 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis......................................................................................1445 Fuel Meter Symptom Diagnosis..................................................................................................................1445 Low Fuel Warning Light Symptom Diagnosis......................................................................................................1446 Oil Pressure Warning Light Symptom Diagnosis..................................................................................................1446 Brake and Parking Brake Warning Light Symptom Diagnosis.......................................................................................1447 Seat Belt Reminder Light Symptom Diagnosis....................................................................................................1447 A/T Shift Position Indicator Symptom Diagnosis (A/T Model)....................................................................................1447 Charge Warning Light Symptom Diagnosis........................................................................................................1448 Main Beam (High Beam) Indicator Symptom Diagnosis.............................................................................................1448 Warning Buzzer Circuit Symptom Diagnosis......................................................................................................1448 Cigarette Lighter Symptom Diagnosis (If Equipped).............................................................................................1449 Horn Symptom Diagnosis........................................................................................................................1449 Information Display Symptom Diagnosis (If Equipped)...........................................................................................1449 Clock System Diagnosis (If Equipped)..........................................................................................................1450 Audio System Symptom Diagnosis (If Equipped)..................................................................................................1451 Remote Audio Control Switch Symptom Diagnosis (If Equipped)...................................................................................1452 Navigation Symptom Diagnosis (If Equipped)....................................................................................................1452 Repair Instructions...............................................................................................................................1453 Ignition Switch Removal and Installation......................................................................................................1453 Ignition Switch Inspection....................................................................................................................1453 Combination Meter Removal and Installation....................................................................................................1453 Fuel Level Sensor Removal and Installation....................................................................................................1454 Fuel Level Sensor Inspection..................................................................................................................1454 Oil Pressure Switch Removal and Installation..................................................................................................1454 Oil Pressure Switch Inspection................................................................................................................1454 Engine Coolant Temperature (ECT) Sensor Inspection............................................................................................1455 Brake Fluid Level Switch Inspection...........................................................................................................1455 Parking Brake Switch Inspection...............................................................................................................1455 Door Switch (Front / Rear Door) Inspection....................................................................................................1455 Rear End Door Switch Inspection (Hatchback)...................................................................................................1455 Trunk Lid Switch Inspection (Sedan)...........................................................................................................1456 Outside Air Temperature Sensor Removal and Installation (If Equipped).........................................................................1456 Outside Air Temperature Sensor Inspection (If Equipped).......................................................................................1456 Instrument Panel Removal and Installation.....................................................................................................1456 Information Display (Clock) Removal and Installation..........................................................................................1458 Audio Unit Removal and Installation (If Equipped).............................................................................................1458 Front Speaker Removal and Installation (If Equipped)..........................................................................................1458 Rear Speaker Removal and Installation (If Equipped)...........................................................................................1459 GPS Antenna Removal and Installation (If Equipped)............................................................................................1459 Horn Removal and Installation.................................................................................................................1459 Horn Inspection...............................................................................................................................1459 Horn Relay Inspection.........................................................................................................................1460 Antenna Base Removal and Installation (Hatchback).............................................................................................1460 Remote Audio Control Switch Removal and Installation (If Equipped)............................................................................1460 Remote Audio Control Switch Inspection (If Equipped)..........................................................................................1461 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)................................................................................1461 Specifications....................................................................................................................................1461 Tightening Torque Specifications..............................................................................................................1461 Wipers / Washers......................................................................................................................................1462 Diagnostic Information and Procedures.............................................................................................................1462 Front Wiper and Washer Symptom Diagnosis......................................................................................................1462 Rear Wiper and Washer Symptom Diagnosis.......................................................................................................1462 Repair Instructions...............................................................................................................................1463 Wipers and Washers Components.................................................................................................................1463 Washer Tank and Washer Pump Removal and Installation..........................................................................................1464 Washer Pump Inspection........................................................................................................................1464 Windshield Wiper Removal and Installation.....................................................................................................1464 Windshield Wiper Motor Inspection.............................................................................................................1465 Rear Wiper Removal and Installation...........................................................................................................1467 Rear Wiper Motor Inspection...................................................................................................................1468 Windshield Wiper and Washer Switch Removal and Installation...................................................................................1469 Windshield Wiper and Washer Switch Inspection.................................................................................................1469 Rear Wiper and Washer Switch Removal and Installation.........................................................................................1471 Rear Wiper and Washer Switch Inspection.......................................................................................................1471 Rear Wiper Relay Removal and Installation.....................................................................................................1471 Rear Wiper Relay Inspection...................................................................................................................1471 Specifications....................................................................................................................................1472 Tightening Torque Specifications..............................................................................................................1472 Glass / Windows / Mirrors.............................................................................................................................1473 Precautions.......................................................................................................................................1473 Precautions for Power Window Service (Pinching Prevention Function Model).....................................................................1473 General Description...............................................................................................................................1473 Rear End Door Window / Back Window Defogger System Description................................................................................1473 Schematic and Routing Diagram.....................................................................................................................1474 Power Window Circuit Diagram (Pinching Prevention Function Model).............................................................................1474 Diagnostic Information and Procedures.............................................................................................................1475 Rear End Door Window / Back Window Defogger Symptom Diagnosis.................................................................................1475 Power Window Control System Symptom Diagnosis.................................................................................................1475 Inspection of Pinching Prevention Function (Pinching Prevention Function Model)...............................................................1476 Power Door Mirror Control System Symptom Diagnosis............................................................................................1476 Door Mirror Heater Symptom Diagnosis (If Equipped)............................................................................................1477 Repair Instructions...............................................................................................................................1477 Windshield Components.........................................................................................................................1477 Windshield Removal and Installation...........................................................................................................1478 Front Pillar Window Components................................................................................................................1482 Front Pillar Window Removal and Installation..................................................................................................1482 Rear Quarter Window Components (Hatchback Model)..............................................................................................1483 Rear Quarter Window Removal and Installation (Hatchback Model)................................................................................1483 Rear End Door Window Components (Hatchback Model).............................................................................................1484 Rear End Door Glass Removal and Installation (Hatchback Model)................................................................................1484 Back Window Components (Sedan Model)..........................................................................................................1485 Back Window Removal and Installation (Sedan Model)............................................................................................1485 Front Door Window Components..................................................................................................................1486 Front Door Glass Removal and Installation.....................................................................................................1487 Front Door Window Regulator Removal and Installation..........................................................................................1488 Front Door Window Regulator Inspection........................................................................................................1488 Rear Door Window Components...................................................................................................................1489 Rear Door Glass Removal and Installation......................................................................................................1490 Rear Door Window Regulator Removal and Installation...........................................................................................1491 Rear Door Window Regulator Inspection.........................................................................................................1492 Rear End Door Window / Back Window Defogger Switch Inspection.................................................................................1492 Rear End Door Window / Back Window Defogger Relay Inspection..................................................................................1492 Rear End Door Window / Back Window Defogger Wire Inspection...................................................................................1493 Rear End Door Window / Back Window Defogger Wire Repair.......................................................................................1494 Power Window Main Switch Inspection...........................................................................................................1494 Power Window Sub Switch Inspection............................................................................................................1496 Pulse Sensor and Its Circuit Inspection (Pinching Prevention Function Model)..................................................................1497 Power Window Main Switch Initialization (Pinching Prevention Function Model)..................................................................1498 Door Mirror Components........................................................................................................................1498 Door Mirror Removal and Installation..........................................................................................................1499 Power Door Mirror Switch Inspection...........................................................................................................1499 Power Door Mirror Actuator Inspection.........................................................................................................1499 Door Mirror Heater Inspection (If Equipped)...................................................................................................1499 Door Mirror Heater Switch Inspection (If Equipped)............................................................................................1500 Special Tools and Equipment.......................................................................................................................1500 Recommended Service Material..................................................................................................................1500 Security and Locks....................................................................................................................................1501 General Description...............................................................................................................................1501 Key Coding Construction.......................................................................................................................1501 Rear End Door Opener System Description.......................................................................................................1501 Component Location................................................................................................................................1502 Power Door Lock and Keyless Entry System Component Location...................................................................................1502 Diagnostic Information and Procedures.............................................................................................................1503 Power Door Lock System Symptom Diagnosis......................................................................................................1503 Power Door Lock System Operation Inspection...................................................................................................1503 Keyless Entry System Symptom Diagnosis........................................................................................................1504 Keyless Entry System Operation Inspection.....................................................................................................1505 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)....................................................................1505 Rear End Door Opener System Symptom Diagnosis.................................................................................................1505 Rear End Door Opener System Operation Inspection..............................................................................................1505 Repair Instructions...............................................................................................................................1506 Front Door Lock Assembly Components...........................................................................................................1506 Front Door Lock Assembly Removal and Installation.............................................................................................1506 Front Door Lock Assembly Inspection...........................................................................................................1508 Power Door Lock Switch Inspection.............................................................................................................1508 Door Key Cylinder Switch Inspection...........................................................................................................1508 Power Door Lock Actuator Inspection...........................................................................................................1509 Rear Door Lock Assembly Components............................................................................................................1510 Rear Door Lock Assembly Removal and Installation..............................................................................................1510 Rear Door Lock Assembly Inspection............................................................................................................1510 Rear End Door Lock Assembly Components (Hatchback Model)......................................................................................1511 Rear End Door Lock Assembly Removal and Installation (Hatchback Model)........................................................................1512 Rear End Door Lock Assembly Inspection (Hatchback Model)......................................................................................1512 Rear End Door Opener Switch Inspection (Hatchback Model)......................................................................................1513 Trunk Lid Lock Assembly Components (Sedan Model)..............................................................................................1513 Trunk Lid Lock Assembly Removal and Installation (Sedan Model)................................................................................1514 Trunk Lid Lock Assembly Inspection (Sedan Model)..............................................................................................1515 Replacement of Transmitter Battery (Other than Keyless Start Model)...........................................................................1515 Programming Transmitter Code for Keyless Entry System (Other than Keyless Start Model)........................................................1515 Keyless Entry Answer Back Function Change- over Procedure.....................................................................................1516 Keyless Entry Receiver Removal and Installation...............................................................................................1516 Keyless Entry Receiver and Its Circuit Inspection.............................................................................................1517 Specifications....................................................................................................................................1518 Tightening Torque Specifications..............................................................................................................1518 Special Tools and Equipment.......................................................................................................................1518 Recommended Service Material..................................................................................................................1518 Seats.................................................................................................................................................1519 Diagnostic Information and Procedures.............................................................................................................1519 Front Seat Heater Symptom Diagnosis (If Equipped).............................................................................................1519 Repair Instructions...............................................................................................................................1520 Front Seat Components.........................................................................................................................1520 Front Seat Removal and Installation...........................................................................................................1521 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped).................................................................1521 Front Seat Heater Wire Inspection (If Equipped)...............................................................................................1521 Rear Seat Components..........................................................................................................................1522 Rear Seat Removal and Installation............................................................................................................1524 Specifications....................................................................................................................................1524 Tightening Torque Specifications..............................................................................................................1524 Special Tools and Equipment.......................................................................................................................1524 Recommended Service Material..................................................................................................................1524 Interior Trim.........................................................................................................................................1525 Repair Instructions...............................................................................................................................1525 Floor Carpet Removal and Installation.........................................................................................................1525 Head Lining Removal and Installation..........................................................................................................1526 Console Box Components........................................................................................................................1528 Specifications....................................................................................................................................1528 Tightening Torque Specifications..............................................................................................................1528 Hood / Fenders / Doors................................................................................................................................1529 Repair Instructions...............................................................................................................................1529 Hood Removal and Installation.................................................................................................................1529 Hood Inspection and Adjustment................................................................................................................1529 Front Fender Components.......................................................................................................................1530 Front Fender Removal and Installation.........................................................................................................1530 Front Door Assembly Components................................................................................................................1531 Front Door Assembly Removal and Installation..................................................................................................1531 Rear Door Assembly Components.................................................................................................................1533 Rear Door Assembly Removal and Installation...................................................................................................1533 Rear End Door Assembly Components (Hatchback Model)...........................................................................................1534 Rear End Door Assembly Removal and Installation (Hatchback Model).............................................................................1535 Trunk Lid Components (Sedan Model)............................................................................................................1536 Trunk Lid Removal and Installation (Sedan Model)..............................................................................................1537 Specifications....................................................................................................................................1539 Tightening Torque Specifications..............................................................................................................1539 Special Tools and Equipment.......................................................................................................................1539 Recommended Service Material..................................................................................................................1539 Body Structure........................................................................................................................................1540 Repair Instructions...............................................................................................................................1540 Front Bumper and Rear Bumper Components.......................................................................................................1540 Radiator Grille Removal and Installation......................................................................................................1541 Front Bumper Extension Removal and Installation (if equipped).................................................................................1542 Rear Bumper Extension Removal and Installation (if equipped)..................................................................................1543 Cowl Top and Front Lower Crossmember Components...............................................................................................1544 Specifications....................................................................................................................................1545 Body Dimensions...............................................................................................................................1545 Panel Clearance...............................................................................................................................1557 Tightening Torque Specifications..............................................................................................................1558 Paint / Coatings......................................................................................................................................1559 General Description...............................................................................................................................1559 Anti-Corrosion Treatment Construction.........................................................................................................1559 Plastic Parts Finishing.......................................................................................................................1559 Component Location................................................................................................................................1560 Sealant Application Areas.....................................................................................................................1560 Under Coating Application Areas...............................................................................................................1568 Anti-Corrosion Compound Application Area......................................................................................................1570 Exterior Trim.........................................................................................................................................1572 Repair Instructions...............................................................................................................................1572 Roof Molding Removal and Installation.........................................................................................................1572 Splash Guard Removal and Installation (If Equipped)...........................................................................................1573 Specifications....................................................................................................................................1573 Tightening Torque Specifications..............................................................................................................1573 Control Systems...........................................................................................................................................1575 Precautions...........................................................................................................................................1577 Precautions.......................................................................................................................................1577 Precautions for Control Systems...............................................................................................................1577 Body Electrical Control System........................................................................................................................1578 Precautions.......................................................................................................................................1578 Precautions in Diagnosing Trouble.............................................................................................................1578 General Description...............................................................................................................................1578 BCM General Description.......................................................................................................................1578 CAN Communication System Description..........................................................................................................1579 Theft Deterrent Light Description.............................................................................................................1580 Security Alarm Description (If Equipped)......................................................................................................1580 Schematic and Routing Diagram.....................................................................................................................1581 Body Electrical Control System Wiring Circuit Diagram.........................................................................................1581 Connector Layout Diagram of BCM and Junction Block............................................................................................1584 Component Location................................................................................................................................1585 BCM and Related System Component Location.....................................................................................................1585 Diagnostic Information and Procedures.............................................................................................................1586 BCM Self-Diagnosis Function...................................................................................................................1586 Body Electrical Control System Check..........................................................................................................1587 Scan Tool Data................................................................................................................................1589 DTC Table.....................................................................................................................................1591 DTC Check.....................................................................................................................................1592 DTC Clearance.................................................................................................................................1593 BCM Power Circuit and Ground Circuit Check....................................................................................................1594 DTC B1133 (No. 1133): Battery Voltage Too High................................................................................................1595 DTC B1141 / B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction...................................1596 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction...............................................................................1597 DTC B1157 (No. 1157): Air Bag Deployment Signal Input.........................................................................................1598 DTC B1170 (No. 1170): EEPROM Access Error.....................................................................................................1598 DTC U0073 (No. 0073): Control Module Communication Bus Off....................................................................................1598 DTC U0100 (No. 0100): Lost Communication with ECM.............................................................................................1598 DTC U0101 (No. 0101): Lost Communication with TCM.............................................................................................1598 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module...................................................1598 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module....................................................................1598 Inspection of BCM and Its Circuits............................................................................................................1599 Repair Instructions...............................................................................................................................1606 BCM (Included in Junction Block) Removal and Installation.....................................................................................1606 Security Alarm Mode Selection Procedure (If Equipped).........................................................................................1607 Outside Air Temperature Sensor Removal and Installation.......................................................................................1607 Outside Air Temperature Sensor Inspection.....................................................................................................1607 Special Tools and Equipment.......................................................................................................................1607 Special Tool..................................................................................................................................1607 Immobilizer Control System............................................................................................................................1608 Precautions.......................................................................................................................................1608 Precautions in Diagnosing Troubles............................................................................................................1608 Precaution in Replacing ECM...................................................................................................................1608 Precaution in Replacing Ignition Key..........................................................................................................1608 Precautions in Handling Immobilizer Control System............................................................................................1608 General Description...............................................................................................................................1609 Immobilizer Control System Introduction.......................................................................................................1609 On-Board Diagnostic System Description (Self-diagnosis Function)..............................................................................1609 Schematic and Routing Diagram.....................................................................................................................1610 Immobilizer Control System Wiring Circuit Diagram.............................................................................................1610 Component Location................................................................................................................................1612 Immobilizer Control System Components Location................................................................................................1612 Diagnostic Information and Procedures.............................................................................................................1612 Immobilizer Control System Check..............................................................................................................1612 DTC Check.....................................................................................................................................1613 DTC Clearance.................................................................................................................................1613 DTC Table.....................................................................................................................................1614 Scan Tool Data................................................................................................................................1615 Immobilizer Indicator Light Does Not Come ON with Ignition Switch ON and Engine Stop..........................................................1616 Immobilizer Indicator Light Remains ON after Engine Start.....................................................................................1617 DTC P1614: Transponder Response Error.........................................................................................................1617 DTC P1615: Steering Lock Unit Communication Error.............................................................................................1618 DTC P1616: Unregistered Keyless Start Control Module..........................................................................................1619 DTC P1618: Keyless Start Control Module CAN Communication Error...............................................................................1620 DTC P1621: Immobilizer Communication Line Error...............................................................................................1620 DTC P1622: EEPROM Reading / Writing Error.....................................................................................................1621 DTC P1623: Unregistered Transponder...........................................................................................................1621 DTC P1625: Immobilizer Antenna Error..........................................................................................................1622 DTC P1636: Immobilizer Information Registration Failure.......................................................................................1622 DTC P1638: Immobilizer Information Mismatched.................................................................................................1623 Inspection of ICM and Its Circuit.............................................................................................................1624 Repair Instructions...............................................................................................................................1626 ICM Removal and Installation..................................................................................................................1626 Registration of the Ignition Key..............................................................................................................1626 Procedure after ECM Replacement...............................................................................................................1626 Special Tools and Equipment.......................................................................................................................1627 Special Tool..................................................................................................................................1627 Keyless Start System..................................................................................................................................1628 Precautions.......................................................................................................................................1628 Precautions in Diagnosing Troubles............................................................................................................1628 General Description...............................................................................................................................1629 Keyless Start System Description..............................................................................................................1629 Parts and Functions...........................................................................................................................1630 Keyless Engine Start Function.................................................................................................................1631 Door Lock Function of Keyless Start System....................................................................................................1632 Trunk Lid Opener Function of Keyless Start System (Sedan).....................................................................................1633 Operation Area of Remote Controller...........................................................................................................1634 Alarm Function................................................................................................................................1635 CAN Communication System Description..........................................................................................................1635 Schematic and Routing Diagram.....................................................................................................................1636 Keyless Start System Electric Wiring Circuit Diagram..........................................................................................1636 Diagnostic Information and Procedures.............................................................................................................1637 Self-Diagnosis Function.......................................................................................................................1637 Keyless Start System Diagnosis Introduction...................................................................................................1637 Keyless Start System Check....................................................................................................................1637 Customer Questionnaire (Example)..............................................................................................................1638 Key Indicator Light Check.....................................................................................................................1638 DTC Check.....................................................................................................................................1639 DTC Table.....................................................................................................................................1640 DTC Clearance.................................................................................................................................1640 Keyless Start System Symptom Diagnosis........................................................................................................1641 Keyless Start System Operation Inspection.....................................................................................................1643 Door Lock Operation (Keyless Start System)....................................................................................................1643 Inspection of Keyless Start Control Module and Its Circuits...................................................................................1643 No DTC Detection After Performing DTC Check...................................................................................................1649 Key Indicator Light Circuit Check (Key Indicator Light Doesn’t Light when Ignition Knob Switch is Pushed).....................................1650 Keyless Start Control Module Power and Ground Circuit Check...................................................................................1652 DTC No. 11: Communication Error with Steering Lock Unit.......................................................................................1653 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction............................................1654 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM Reading Error) / (EEPROM Writing Error)...........................1654 DTC No. 31: Lost Communication with BCM.......................................................................................................1655 DTC No. 33: Control Module Communication Bus Off..............................................................................................1655 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door / Trunk Lid Request Switch Failure.................................1655 Repair Instructions...............................................................................................................................1656 Antennas and Request Switches Removal and Installation........................................................................................1656 Front Door (Driver and Passenger Side), Rear End Door / Trunk Lid Request Switch Inspection...................................................1657 Steering Lock Unit Removal and Installation...................................................................................................1657 Steering Lock Unit Inspection.................................................................................................................1657 Front Door Lock Switch Inspection.............................................................................................................1658 Keyless Start Control Module Removal and Installation.........................................................................................1658 Remote Controller Inspection..................................................................................................................1658 Replacement of Remote Controller Battery......................................................................................................1658 Registration Procedure for Remote Controller ID Code..........................................................................................1659 Keyless Start Registration....................................................................................................................1660 COPYRIGHT.................................................................................................................................................1661 BOOKCOVER_VOL1............................................................................................................................................1662 BOOKCOVER_VOL2............................................................................................................................................1663
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