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SUZUKI SX4 RW416D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI SX4 RW416D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI SX4 RW416D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 645
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI SX4 RW416D SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
START .................................................................................................................................................... 5 IMPORTANT ................................................................................................................................................ 1 FOREWORD ................................................................................................................................................. 3 TABLE OF CONTENTS......................................................................................................................................... 5 Precautions............................................................................................................................................... 7 Precautions........................................................................................................................................... 8 Precautions....................................................................................................................................... 8 General Precautions........................................................................................................................... 8 Precaution for Vehicle Equipped with ESP‚ System.............................................................................................. 11 Precautions for Catalytic Converter........................................................................................................... 11 General Information....................................................................................................................................... 13 General Information................................................................................................................................... 14 General Description............................................................................................................................... 14 Abbreviations................................................................................................................................. 14 Engine Identification Number.................................................................................................................. 15 Component Location................................................................................................................................ 15 Warning, Caution and Information Labels Location.............................................................................................. 15 Maintenance and Lubrication........................................................................................................................... 17 Scheduled Maintenance............................................................................................................................. 17 Maintenance Schedule under Normal Driving Conditions.......................................................................................... 17 Maintenance Recommended under Severe Driving Conditions....................................................................................... 18 Repair Instructions............................................................................................................................... 19 Accessory Drive Belt Inspection............................................................................................................... 19 Camshaft Timing Belt Replacement.............................................................................................................. 19 Engine Oil and Oil Filter Change.............................................................................................................. 19 Engine Coolant Inspection..................................................................................................................... 21 Engine Coolant Change......................................................................................................................... 21 Exhaust System Inspection..................................................................................................................... 21 Air Cleaner Filter Inspection................................................................................................................. 21 Air Cleaner Filter Replacement................................................................................................................ 21 Fuel Filter Replacement....................................................................................................................... 21 Water Draining of Fuel Filter................................................................................................................. 21 Clutch Fluid Inspection....................................................................................................................... 22 Specifications.................................................................................................................................... 22 Tightening Torque Specifications.............................................................................................................. 22 Special Tools and Equipment....................................................................................................................... 22 Recommended Fluids and Lubricants............................................................................................................. 22 Engine.................................................................................................................................................... 23 Precautions........................................................................................................................................... 28 Precautions....................................................................................................................................... 28 Precautions for Engine........................................................................................................................ 28 Engine General Information and Diagnosis.............................................................................................................. 29 Precautions....................................................................................................................................... 29 Precautions on Engine Service................................................................................................................. 29 Precautions in Diagnosing Trouble............................................................................................................. 29 Statement on Cleanliness and Care............................................................................................................. 30 General Description............................................................................................................................... 30 Engine Diagnosis General Description.......................................................................................................... 30 OBD System Description........................................................................................................................ 30 CAN Communication System Description.......................................................................................................... 32 Electronic Control System Description......................................................................................................... 33 Component Location................................................................................................................................ 38 Electronic Control System Components Location................................................................................................. 38 Diagnostic Information and Procedures............................................................................................................. 39 Malfunction Indicator Lamp (MIL) Check........................................................................................................ 39 Service Vehicle Soon (SVS) Light Check........................................................................................................ 39 Engine and Emission Control System Check...................................................................................................... 40 DTC Check..................................................................................................................................... 42 DTC Clearance................................................................................................................................. 42 DTC Confirmation Procedure.................................................................................................................... 43 DTC Table..................................................................................................................................... 43 Scan Tool Data................................................................................................................................ 49 Visual Inspection............................................................................................................................. 53 Engine Basic Inspection....................................................................................................................... 54 Engine Symptom Diagnosis...................................................................................................................... 54 DTC P0001 / P0003 / P0004: Fuel Flow Actuator Control Circuit Open / Low / High............................................................... 73 DTC P0002: Fuel Flow Actuator Control Circuit Range / Performance............................................................................. 74 DTC P0016: Crankshaft Position - Camshaft Position Correlation................................................................................ 74 DTC P0069: Boost Pressure - Barometric Pressure Correlation................................................................................... 76 DTC P0087 / P0088: Fuel Rail Pressure - Too Low / High........................................................................................ 77 DTC P0093: Fuel System Large Leak Detected.................................................................................................... 77 DTC P0097 / P0098: IAT Sensor-2 Circuit Low / High............................................................................................ 78 DTC P0100: MAF Circuit........................................................................................................................ 79 DTC P0102 / P0103 / P0104: MAF Circuit Low Input / High Input / Intermittent.................................................................. 79 DTC P0107 / P0108: Barometric Pressure Circuit Low / High Input............................................................................... 81 DTC P0112 / P0113: IAT Sensor-1 Circuit Low / High............................................................................................ 81 DTC P0115 / P0116: ECT Circuit Range / Performance............................................................................................ 82 DTC P0117 / P0118: ECT Circuit Low / High..................................................................................................... 84 DTC P0120 / P0121: Inlet Throttle Valve Position Sensor Circuit / Range / Performance......................................................... 84 DTC P0122 / P0123: Inlet Throttle Valve Position Sensor Circuit Low / High.................................................................... 85 DTC P0182 / P0183: Fuel Temperature Sensor Circuit Low / High................................................................................. 86 DTC P0192 / P0193: Fuel Pressure Sensor Circuit Low / High.................................................................................... 87 DTC P0201 / P0202 / P0203 / P0204: Injector Circuit / Open - Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4................................ 88 DTC P0215: Double Relay Circuit Malfunction................................................................................................... 89 DTC P0222 / P0223: APP Sensor (Main) Circuit Low / High....................................................................................... 90 DTC P0227 / P0228: APP Sensor (Sub) Circuit Low / High........................................................................................ 90 DTC P0234 / P0299: Turbocharger Overboost Condition / Underboost Condition.................................................................... 90 DTC P0237 / P0238: Boost Pressure Sensor Circuit Low / High................................................................................... 92 DTC P0243 / P0245 / P0246: Boost Pressure Control Solenoid Valve Circuit / Low / High......................................................... 93 DTC P0262 / P0265 / P0268 / P0271: Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Injector Circuit High.................................... 94 DTC P0335 / P0339: CKP Sensor Circuit / Intermittent.......................................................................................... 95 DTC P0341 / P0344: CMP Sensor Circuit Range / Performance / Malfunction....................................................................... 96 DTC P0401 / P0402: EGR Flow Insufficient Detected / Excessive Detected........................................................................ 97 DTC P0405 / P0406: EGR Position Sensor Circuit Low / High..................................................................................... 98 DTC P0409: EGR Position Sensor Circuit........................................................................................................ 99 DTC P0483 / P0494: Fan Rationality Check / Fan Speed Low......................................................................................100 DTC P0487 / P0488: Inlet Throttle Valve Control Circuit Range / Performance...................................................................101 DTC P0489 / P0490: EGR Control Circuit Low / High.............................................................................................102 DTC P0500: Vehicle Speed Sensor...............................................................................................................103 DTC P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit Low / High.........................................................................103 DTC P0562 / P0563: System Voltage Low / High..................................................................................................105 DTC P0603: Internal Control Module Keep Alive Memory (KAM) Error..............................................................................105 DTC P0606: ECM Processor......................................................................................................................106 DTC P0650 / P1642: Malfunction Indicator Lamp (MIL) Control Circuit / Open....................................................................106 DTC P0658 / P0659: Sensor Power Supply Circuit 1 Low / High...................................................................................108 DTC P0686 / P0687 / P1639 / P1640: Double Relay Control Circuit Low / High / Open / Range / Performance.......................................110 DTC P0691 / P0692: Radiator Cooling Fan Relay No.1 Control Circuit Low / High.................................................................111 DTC P0693 / P0694: Radiator Cooling Fan Relay No.2 and No.3 Control Circuit Low / High........................................................112 DTC P0695 / P0696: Radiator Cooling Sub Fan Control Circuit Low / High........................................................................114 DTC P0704: CPP Switch Signal Circuit Malfunction..............................................................................................115 DTC P1113 / P1166: Fuel Pressure Too Low / High...............................................................................................116 DTC P1161: Inlet Throttle Valve Stuck On......................................................................................................116 DTC P1162: EGR Valve Stuck On.................................................................................................................117 DTC P1197: Injector Circuit Malfunction.......................................................................................................117 DTC P1199: Fuel Level Sensor Malfunction......................................................................................................118 DTC P1349 / P1350: Glow Plug Control Module Monitor Circuit High / Low........................................................................118 DTC P1351 / P1352: Glow Plug Control Module Stuck On / Performance............................................................................120 DTC P1366 / P1367 / P1368 / P1369: Injector Malfunction - Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4...................................121 DTC P1461 / P1462: EGR Valve Position Learning Long Time Drift / Short Time Drift.............................................................122 DTC P1471 / P2141 / P2142: Inlet Throttle Valve Control Circuit Open / Malfunction / Low / High...............................................123 DTC P1506: A/C Switch Signal Malfunction......................................................................................................124 DTC P1543: A/C Compressor Relay Circuit.......................................................................................................125 DTC P1586 / P1587: Sensor Power Supply Circuit 3 Low / High...................................................................................126 DTC P1589 / P1590: MAF Sensor Power Supply Circuit Low / High.................................................................................128 DTC P1600: Injector Quantity Adjustment.......................................................................................................129 DTC P1631: Engine Overspeed Condition.........................................................................................................129 DTC P1633 / P1634: Supply Voltage of Below Limit / Above Limit................................................................................130 DTC P1637 / P1638: System Voltage Low / High..................................................................................................130 DTC P1641: SPI Communication..................................................................................................................131 DTC P1667: ADC Monitoring.....................................................................................................................131 DTC P1811: Control Module Program Error.......................................................................................................131 DTC P2111: Inlet Throttle Valve Position Sensor - Stuck Open..................................................................................132 DTC P2138: APP Sensor (Main) / (Sub) Voltage Correlation......................................................................................133 DTC P2143 / P2144 / P2145: EGR Control Circuit / Open / Low / High............................................................................133 DTC P2146 / P2148: Fuel Injector Supply Voltage Circuit / Open / High.........................................................................135 DTC P2299: Brake Pedal Position / Accelerator Pedal Position Correlation......................................................................135 DTC P2413: EGR System Performance.............................................................................................................136 DTC P2530: Ignition Switch Circuit............................................................................................................136 DTC P2670 / P2671: Sensor Power Supply Circuit 2 Low / High...................................................................................138 DTC P3007 / P3008: MAF Too High / Low.........................................................................................................140 DTC U0121: Lost Communication with ABS Control Module.........................................................................................141 DTC U0122: Lost Communication with ESP‚ Control Module........................................................................................141 DTC U0140: Lost Communication with BCM........................................................................................................141 DTC U0416: Invalid Data Received From ESP‚ Control Module.....................................................................................141 DTC U1003: Control Module Communication Bus Off...............................................................................................142 Table A-1: Injector Circuit Check.............................................................................................................144 Table A-2: Fuel Temperature Sensor Check......................................................................................................146 Table A-3: Fuel Pressure Sensor Circuit Check.................................................................................................147 Table A-4: Fuel Flow Actuator Operation Check.................................................................................................148 Table A-5: Low-Pressure Fuel Supply Circuit Check.............................................................................................149 Table A-6: High-Pressure Fuel Supply Circuit Check............................................................................................154 Table B-1: Air Intake / Vacuum / Turbocharger Circuit Check...................................................................................156 Table B-2: MAF Sensor Operation Check.........................................................................................................157 Table B-3: Boost Pressure Sensor Operation Check..............................................................................................158 Table B-4: Barometric Pressure Check..........................................................................................................159 Table B-5: EGR Valve Operation Check..........................................................................................................160 Table B-6: Inlet Throttle Valve Operation Check...............................................................................................161 Table B-7: Boost Pressure Control Solenoid Valve Check........................................................................................162 Table C-1: Battery Voltage Check..............................................................................................................163 Table C-2: Double Relay Operation Check.......................................................................................................164 Table C-3: Engine Speed Check.................................................................................................................166 Table C-4: ECT Sensor Operation Check.........................................................................................................167 Table C-5: IAT Sensor-1 Check.................................................................................................................168 Table C-6: IAT Sensor-2 Check.................................................................................................................169 Table C-7: APP Sensor Check...................................................................................................................170 Table C-8: VSS Signal Check...................................................................................................................172 Table C-9: Glow Plugs Operation Check.........................................................................................................172 Table C-10: Radiator Cooling Fan Operation Check..............................................................................................175 Repair Instructions...............................................................................................................................179 Idle Speed Inspection.........................................................................................................................179 Special Tools and Equipment.......................................................................................................................179 Special Tool..................................................................................................................................179 Aux. Emission Control Devices.........................................................................................................................180 Repair Instructions...............................................................................................................................180 EGR Valve Inspection..........................................................................................................................180 Engine Electrical Devices.............................................................................................................................181 Precautions.......................................................................................................................................181 Precaution in Replacing ECM...................................................................................................................181 General Description...............................................................................................................................181 ECM Registration..............................................................................................................................181 Repair Instructions...............................................................................................................................182 Engine Control Module (ECM) Removal and Installation..........................................................................................182 Registration for ECM Replacement..............................................................................................................182 Fuel Injector Calibration Code Registration...................................................................................................183 Vehicle Valiant Date Registration.............................................................................................................183 EGR Valve Date Initialization.................................................................................................................183 Inlet Throttle Valve Date Initialization......................................................................................................183 Glow Plug Control Module Removal and Installation.............................................................................................183 Glow Plug Control Module Inspection...........................................................................................................183 Glow Plug Removal and Installation............................................................................................................184 Glow Plug Inspection..........................................................................................................................184 MAF Sensor and IAT Sensor-1 Removal and Installation..........................................................................................184 IAT Sensor-1 Inspection.......................................................................................................................185 Boost Pressure Sensor Removal and Installation................................................................................................185 Boost Pressure Sensor Inspection..............................................................................................................186 IAT Sensor-2 Removal and Installation.........................................................................................................186 IAT Sensor-2 Inspection.......................................................................................................................186 Oil Temperature Sensor Removal and Installation...............................................................................................186 Oil Temperature Sensor Inspection.............................................................................................................187 ECT Sensor Removal and Installation...........................................................................................................187 ECT Sensor Inspection.........................................................................................................................187 CMP Sensor Removal and Installation...........................................................................................................188 CMP Sensor Inspection.........................................................................................................................188 CKP Sensor Removal and Installation...........................................................................................................189 CKP Sensor Inspection.........................................................................................................................189 Double Relay Removal and Installation.........................................................................................................189 Double Relay Inspection.......................................................................................................................190 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection........................................................................191 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation.....................................................................191 Accelerator Pedal Position (APP) Sensor Assembly Inspection...................................................................................192 Starting Motor Control Relay Inspection.......................................................................................................192 Boost Pressure Control Solenoid Valve Removal and Installation................................................................................193 Boost Pressure Control Solenoid Valve Inspection..............................................................................................193 Inlet Throttle Valve Inspection...............................................................................................................193 Specifications....................................................................................................................................194 Tightening Torque Specifications..............................................................................................................194 Special Tools and Equipment.......................................................................................................................194 Special Tool..................................................................................................................................194 Engine Mechanical.....................................................................................................................................195 Precautions.......................................................................................................................................195 Precaution on Crankshaft Timing Pulley........................................................................................................195 Diagnostic Information and Procedures.............................................................................................................196 Compression Check.............................................................................................................................196 Vacuum Pump Inspection........................................................................................................................196 Repair Instructions...............................................................................................................................197 Air Cleaner Components........................................................................................................................197 Air Cleaner Filter Removal and Installation...................................................................................................198 Air Cleaner Filter Inspection and Cleaning....................................................................................................198 Air Cleaner Assembly Removal and Installation.................................................................................................199 Intercooler Components........................................................................................................................200 Intercooler Removal and Installation..........................................................................................................200 Intercooler Inspection and Cleaning...........................................................................................................201 Turbocharger Assembly Components..............................................................................................................201 Turbocharger Assembly Removal and Installation................................................................................................202 Turbocharger Assembly Inspection..............................................................................................................203 EGR Cooler and EGR Pipe Removal and Installation..............................................................................................203 EGR Valve Removal and Installation............................................................................................................204 Inlet Throttle Valve Removal and Installation.................................................................................................204 Vacuum Pump Removal and Installation..........................................................................................................205 Intake Manifold and Cylinder Head Cover Components............................................................................................206 Cylinder Head Cover Removal and Installation..................................................................................................207 Intake Manifold Removal and Installation......................................................................................................207 Engine Mounting Components....................................................................................................................208 Engine Assembly Removal and Installation......................................................................................................209 Timing Belt and Belt Tensioner Components.....................................................................................................213 Timing Belt and Belt Tensioner Removal and Installation.......................................................................................214 Camshaft Housing Components...................................................................................................................218 Camshaft Housing Assembly Removal and Installation............................................................................................219 Camshaft, Valve Rocker and Hydraulic Valve Adjuster Components................................................................................223 Camshaft, Valve Rocker and Hydraulic Valve Adjuster Removal and Installation..................................................................224 Camshaft, Camshaft housing Valve Rocker and Hydraulic Valve Adjuster Inspection...............................................................226 Valve and Cylinder Head Components............................................................................................................227 Cylinder Head Assembly Removal and Installation...............................................................................................228 Valve and Cylinder Head Assembly Inspection...................................................................................................230 Cylinder Head Assembly Disassembly and Reassembly.............................................................................................231 Valve, Valve Guide and Valve Seat Inspection..................................................................................................232 Cylinder Head Inspection......................................................................................................................232 Valve Spring Inspection.......................................................................................................................233 Cylinder Head and Related Parts Specification (for Reference).................................................................................233 Cylinder Head Bolt Inspection.................................................................................................................233 Lower Crankcase, Main Bearing, Crankshaft, Piston and Connecting Rod Assembly Components......................................................234 Lower Crankcase, Main Bearing, Crankshaft, Piston and Connecting Rod Assembly Removal and Installation........................................235 Piston and Connecting Rod Assembly Disassembly and Reassembly.................................................................................240 Cylinder, Piston, Piston Ring and Piston Pin Inspection.......................................................................................241 Piston Pins and Connecting Rod Inspection.....................................................................................................241 Piston and Related Parts Specification (for Reference)........................................................................................242 Crank Pin and Connecting Rod Bearing Inspection...............................................................................................242 Crankshaft Inspection.........................................................................................................................242 Main Bearing Inspection.......................................................................................................................243 Thrust Bearing Inspection.....................................................................................................................244 Flywheel Inspection...........................................................................................................................245 Cylinder Block Specification (for Reference)..................................................................................................245 Specifications....................................................................................................................................245 Tightening Torque Specifications..............................................................................................................245 Special Tools and Equipment.......................................................................................................................247 Recommended Service Material..................................................................................................................247 Special Tool..................................................................................................................................247 Engine Lubrication System.............................................................................................................................249 General Description...............................................................................................................................249 Engine Lubrication Description................................................................................................................249 Diagnostic Information and Procedures.............................................................................................................249 Oil Pressure Check............................................................................................................................249 Repair Instructions...............................................................................................................................250 Heat Exchanger and Oil Filter Block Components................................................................................................250 Heat Exchanger and Oil Filter Block Removal and Installation..................................................................................251 Oil Pan and Oil Pump Strainer Components......................................................................................................252 Oil Pan and Oil Pump Strainer Removal and Installation........................................................................................253 Oil Pan and Oil Pump Strainer Cleaning........................................................................................................254 Oil Pump Components...........................................................................................................................255 Oil Pump Removal and Installation.............................................................................................................255 Oil Pressure Switch Removal and Installation..................................................................................................257 Specifications....................................................................................................................................258 Tightening Torque Specifications..............................................................................................................258 Special Tools and Equipment.......................................................................................................................259 Recommended Service Material..................................................................................................................259 Special Tool..................................................................................................................................259 Engine Cooling System.................................................................................................................................260 General Description...............................................................................................................................260 Cooling System Description....................................................................................................................260 Coolant Description...........................................................................................................................260 Schematic and Routing Diagram.....................................................................................................................261 Coolant Circulation...........................................................................................................................261 Diagnostic Information and Procedures.............................................................................................................262 Engine Cooling Symptom Diagnosis..............................................................................................................262 Repair Instructions...............................................................................................................................263 Cooling System Components.....................................................................................................................263 Coolant Level Check...........................................................................................................................264 Engine Cooling System Inspection and Cleaning.................................................................................................264 Cooling System Draining.......................................................................................................................265 Cooling System Refilling......................................................................................................................265 Cooling System Flushing.......................................................................................................................266 Cooling Water Pipe or Hose Removal and Installation...........................................................................................266 Radiator Cooling Fan Motor Inspection.........................................................................................................267 Radiator Cooling Fan Relay Inspection.........................................................................................................267 Radiator Cooling Fan Assembly Removal and Installation........................................................................................268 Radiator Cooling Fan Disassembly and Reassembly...............................................................................................268 Radiator Cooling Sub Fan Removal and Installation.............................................................................................268 Radiator Cooling Sub Fan Inspection...........................................................................................................269 Radiator Inspection and Cleaning..............................................................................................................269 Radiator Removal and Installation.............................................................................................................269 Water Pump Removal and Installation...........................................................................................................270 Water Pump Inspection.........................................................................................................................271 Thermostat Assembly Removal and Installation..................................................................................................271 Specifications....................................................................................................................................272 Tightening Torque Specifications..............................................................................................................272 Fuel System...........................................................................................................................................273 Precautions.......................................................................................................................................273 Precautions on Fuel System Service............................................................................................................273 Fuel System Description.......................................................................................................................276 Repair Instructions...............................................................................................................................277 Fuel System Components........................................................................................................................277 Fuel Pressure Relief Procedure................................................................................................................279 Fuel Leakage Check Procedure..................................................................................................................279 Water Draining of Fuel Filter.................................................................................................................279 Air Bleeding of Fuel System...................................................................................................................279 Fuel Filter and Fuel Heater Removal and Installation..........................................................................................280 Fuel Heater Inspection........................................................................................................................281 Fuel Temperature Sensor Removal and Installation..............................................................................................281 Fuel Temperature Sensor Inspection............................................................................................................281 Fuel Hose Disconnecting and Reconnecting......................................................................................................282 Fuel Lines Inspection.........................................................................................................................283 Fuel Pipe Removal and Installation............................................................................................................284 High Pressure Pipe Removal and Installation...................................................................................................284 Fuel Injector On-Vehicle Inspection...........................................................................................................286 Fuel Injector Removal and Installation........................................................................................................286 High Pressure Pump Removal and Installation...................................................................................................288 Fuel Flow Actuator On-Vehicle Inspection......................................................................................................291 Common Rail and Fuel Pressure Sensor Removal and Installation.................................................................................291 Fuel Pressure Sensor Inspection...............................................................................................................292 Fuel Filler Cap Inspection....................................................................................................................292 Fuel Tank Removal and Installation............................................................................................................292 Fuel Tank Inspection..........................................................................................................................294 Fuel Tank Purging Procedure...................................................................................................................294 Fuel Level Sensor Assembly Removal and Installation...........................................................................................294 Fuel Level Sensor Inspection..................................................................................................................295 Specifications....................................................................................................................................296 Tightening Torque Specifications..............................................................................................................296 Special Tools and Equipment.......................................................................................................................296 Special Tool..................................................................................................................................296 Starting System.......................................................................................................................................298 Diagnostic Information and Procedures.............................................................................................................298 Cranking System Test..........................................................................................................................298 Repair Instructions...............................................................................................................................299 Starting Motor Unit Components................................................................................................................299 Starting Motor Dismounting and Remounting.....................................................................................................299 Specifications....................................................................................................................................300 Tightening Torque Specifications..............................................................................................................300 Charging System.......................................................................................................................................301 General Description...............................................................................................................................301 Generator Description.........................................................................................................................301 Diagnostic Information and Procedures.............................................................................................................302 Generator Symptom Diagnosis...................................................................................................................302 Generator Test (Undercharged Battery Check)...................................................................................................303 Generator Test (Overcharged Battery Check)....................................................................................................303 Repair Instructions...............................................................................................................................304 Generator Unit Components.....................................................................................................................304 Generator Dismounting and Remounting..........................................................................................................304 Generator Drive Belt and Tensioner Removal and Installation...................................................................................305 Generator Drive Belt Inspection...............................................................................................................305 Specifications....................................................................................................................................306 Tightening Torque Specifications..............................................................................................................306 Special Tools and Equipment.......................................................................................................................306 Special Tool..................................................................................................................................306 Exhaust System........................................................................................................................................307 General Description...............................................................................................................................307 Exhaust System Description....................................................................................................................307 Diagnostic Information and Procedures.............................................................................................................307 Exhaust System Check..........................................................................................................................307 Repair Instructions...............................................................................................................................308 Exhaust System Components.....................................................................................................................308 Catalytic Converter Assembly Removal and Installation.........................................................................................309 Exhaust Manifold Components...................................................................................................................310 Exhaust Manifold Removal and Installation.....................................................................................................311 Exhaust Pipe Removal and Installation.........................................................................................................311 Specifications....................................................................................................................................311 Tightening Torque Specifications..............................................................................................................311 Suspension................................................................................................................................................313 Front Suspension......................................................................................................................................314 Repair Instructions...............................................................................................................................314 Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation...............................................................314 Specifications....................................................................................................................................316 Tightening Torque Specifications..............................................................................................................316 Driveline / Axle..........................................................................................................................................317 Drive Shaft / Axle....................................................................................................................................318 Component Location................................................................................................................................318 Front Drive Shaft Assembly Components Location................................................................................................318 Repair Instructions...............................................................................................................................318 Front Drive Shaft Removal and Installation....................................................................................................318 Front Drive Shaft Components..................................................................................................................320 Front Drive Shaft Disassembly and Reassembly..................................................................................................320 Center Shaft and Center Bearing Support Disassembly and Reassembly............................................................................324 Specifications....................................................................................................................................325 Tightening Torque Specifications..............................................................................................................325 Special Tools and Equipment.......................................................................................................................325 Recommended Service Material..................................................................................................................325 Special Tool..................................................................................................................................325 Brakes....................................................................................................................................................327 Brake Control System and Diagnosis....................................................................................................................330 General Description...............................................................................................................................330 Front Brake Hose / Pipe Construction..........................................................................................................330 Diagnostic Information and Procedures.............................................................................................................331 Brakes Symptom Diagnosis......................................................................................................................331 Repair Instructions...............................................................................................................................333 Master Cylinder and Brake Fluid Level Inspection..............................................................................................333 Master Cylinder Assembly Components...........................................................................................................334 Master Cylinder Reservoir Removal and Installation............................................................................................335 Master Cylinder Assembly Removal and Installation.............................................................................................336 Specifications....................................................................................................................................337 Tightening Torque Specifications..............................................................................................................337 Special Tools and Equipment.......................................................................................................................337 Recommended Service Material..................................................................................................................337 ABS...................................................................................................................................................338 Precautions.......................................................................................................................................338 Precautions in Diagnosing Troubles............................................................................................................338 General Description...............................................................................................................................339 ABS Description...............................................................................................................................339 CAN Communication System Description..........................................................................................................339 Schematic and Routing Diagram.....................................................................................................................340 ABS Schematic.................................................................................................................................340 ABS Wiring Circuit Diagram....................................................................................................................341 Diagnostic Information and Procedures.............................................................................................................343 DTC Table.....................................................................................................................................343 Serial Data Link Circuit Check................................................................................................................343 DTC 1016: Stop light Switch Circuit...........................................................................................................346 Electronic Stability Program..........................................................................................................................347 Precautions.......................................................................................................................................347 Precautions in Diagnosing Troubles............................................................................................................347 Precautions in On-Vehicle Service.............................................................................................................347 Precautions in Hydraulic Unit Operation Check.................................................................................................348 Precautions in Sensor Calibration.............................................................................................................348 Precautions in Speedometer Test or Other Tests................................................................................................348 General Description...............................................................................................................................349 Electronic Stability Program Description......................................................................................................349 ESP‚ Hydraulic Unit / Control Module Assembly Description.....................................................................................349 Warning Light, Indicator Light Description....................................................................................................350 CAN Communication System Description..........................................................................................................351 Schematic and Routing Diagram.....................................................................................................................352 Electronic Stability Program Schematic........................................................................................................352 Electronic Stability Program Wiring Circuit Diagram...........................................................................................353 Component Location................................................................................................................................355 Electronic Stability Program Component Location...............................................................................................355 Diagnostic Information and Procedures.............................................................................................................356 Electronic Stability Program Check............................................................................................................356 ESP‚ Warning Light Check......................................................................................................................358 ABS Warning Light Check.......................................................................................................................358 EBD Warning Light (Brake Warning Light) Check.................................................................................................358 DTC Check.....................................................................................................................................359 DTC Table.....................................................................................................................................359 DTC Clearance.................................................................................................................................362 Fail-Safe Table...............................................................................................................................363 Scan Tool Data................................................................................................................................365 ESP‚ Warning Light Does Not Come ON at Ignition Switch ON.....................................................................................366 ESP‚ Warning Light Comes ON Steady............................................................................................................367 ABS Warning Light Does Not Come ON at Ignition Switch ON......................................................................................368 ABS Warning Light Comes ON Steady.............................................................................................................369 EBD Warning Light (Brake Warning Light) Comes ON Steady.......................................................................................369 Serial Data Link Circuit Check................................................................................................................371 DTC C1016: Brake Light Switch.................................................................................................................373 DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor.........................................................................................374 DTC C1020 / C1028: Master Cylinder Pressure Sensor Power Supply Failure / Circuit.............................................................375 DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder.............................376 DTC C1024: Steering Angle Sensor..............................................................................................................378 DTC C1027: ESP‚ OFF Switch....................................................................................................................378 DTC C1033: Wheel Speed Sensor Deviation.......................................................................................................379 DTC C1034 / C1039: Yaw Rate Sensor Power Supply Failure / Internal Failure....................................................................381 DTC C1037: Steering Angle Sensor Power Supply Failure.........................................................................................382 DTC C1038: Steering Angle Sensor Detect Rolling Counter.......................................................................................383 DTC C1040: ESP‚ Continuous Operation..........................................................................................................384 DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet / Outlet / Cut / Suction Solenoid....384 DTC C1057: Power Supply Voltage Too High / Too Low............................................................................................386 DTC C1061: Pump Motor Circuit.................................................................................................................387 DTC C1063: Solenoid Valve Power Supply Driver Circuit.........................................................................................388 DTC C1071: Control Module Internal Defect.....................................................................................................389 DTC C1075: Steering Angle Sensor Calibration..................................................................................................389 DTC C1091: CAN Invalid Data from ECM..........................................................................................................390 DTC C1096: Yaw Rate Sensor Message Counter Error..............................................................................................390 DTC U0073: Control Module Communication Bus Off...............................................................................................391 DTC U0100: Lost Communication with ECM / PCM..................................................................................................392 DTC U0123 Lost Communication with Yaw Rate Sensor Module......................................................................................394 DTC U0126: Lost Communication with Steering Angle Sensor......................................................................................395 ESP‚ Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check..................................................................396 Repair Instructions...............................................................................................................................398 ESP‚ Hydraulic Unit Operation Check...........................................................................................................398 Steering Angle Sensor Calibration.............................................................................................................399 ESP‚ Hydraulic unit / control module Assembly On-Vehicle Inspection...........................................................................399 ESP‚ Hydraulic unit / control module Assembly Removal and Installation........................................................................400 Front Wheel Speed Sensor On-Vehicle Inspection................................................................................................403 Front Wheel Speed Sensor Removal and Installation.............................................................................................403 Front Wheel Speed Sensor Inspection...........................................................................................................403 Rear Wheel Speed Sensor On-Vehicle Inspection.................................................................................................403 Rear Wheel Speed Sensor Removal and Installation..............................................................................................403 Rear Wheel Speed Sensor Inspection............................................................................................................403 Front Wheel Speed Sensor Encoder On-Vehicle Inspection........................................................................................403 Front Wheel Speed Sensor Encoder Removal and Installation.....................................................................................403 Rear Wheel Speed Sensor Encoder On-Vehicle Inspection.........................................................................................403 Rear Wheel Speed Sensor Encoder Removal and Installation......................................................................................403 Master Cylinder Pressure Sensor On-Vehicle Inspection.........................................................................................404 Yaw Rate Sensor On-Vehicle Inspection.........................................................................................................404 Yaw Rate Sensor Removal and Installation......................................................................................................405 Yaw Rate Sensor Inspection....................................................................................................................406 Steering Angle Sensor On-Vehicle Inspection...................................................................................................406 Steering Angle Sensor Removal and Installation................................................................................................406 Steering Angle Sensor Inspection..............................................................................................................406 ESP‚ OFF Switch Removal and Installation......................................................................................................407 ESP‚ OFF Switch Inspection....................................................................................................................407 Specifications....................................................................................................................................408 Tightening Torque Specifications..............................................................................................................408 Special Tools and Equipment.......................................................................................................................408 Special Tool..................................................................................................................................408 Transmission / Transaxle..................................................................................................................................409 Manual Transmission/Transaxle.........................................................................................................................410 General Description...............................................................................................................................410 Manual Transaxle Construction.................................................................................................................410 Repair Instructions...............................................................................................................................413 Manual Transaxle Oil Level Check..............................................................................................................413 Manual Transaxle Oil Change...................................................................................................................413 Differential Side Oil Seal Replacement........................................................................................................414 Gear Shift Control Lever and Cable Components.................................................................................................415 Gear Shift Control Lever and Cable Removal and Installation...................................................................................416 Manual Transaxle Unit Components..............................................................................................................416 Manual Transaxle Unit Dismounting and Remounting..............................................................................................417 Gear Shift and Select Shaft Assembly Components...............................................................................................417 Gear Shift and Select Shaft Assembly Removal and Installation.................................................................................418 Gear Shift and Select Shaft Assembly Disassembly and Reassembly...............................................................................420 Manual Transaxle Assembly Components..........................................................................................................421 Manual Transaxle Assembly Disassembly and Reassembly..........................................................................................422 Right Case Disassembly and Reassembly.........................................................................................................425 Left Case Disassembly and Reassembly..........................................................................................................427 Input Shaft, Countershaft and Reverse Gears Components........................................................................................429 Input Shaft Disassembly and Reassembly........................................................................................................430 Countershaft Disassembly and Reassembly.......................................................................................................434 Gear Shift Shaft Components...................................................................................................................438 Gear Shift Shaft and Fork Inspection..........................................................................................................439 Differential Components.......................................................................................................................439 Differential Disassembly and Reassembly.......................................................................................................440 Specifications....................................................................................................................................442 Tightening Torque Specifications..............................................................................................................442 Special Tools and Equipment.......................................................................................................................443 Recommended Service Material..................................................................................................................443 Special Tool..................................................................................................................................443 Clutch................................................................................................................................................445 General Description...............................................................................................................................445 Clutch (Hydraulic Type) Construction..........................................................................................................445 Repair Instructions...............................................................................................................................446 Clutch Pedal Position (CPP) Switch Removal and Installation...................................................................................446 Clutch Pedal Position (CPP) Switch Inspection.................................................................................................446 Clutch Pedal Inspection.......................................................................................................................446 Air Bleeding of Clutch System.................................................................................................................447 Clutch Fluid Pipe Removal and Installation....................................................................................................448 Clutch Operating Cylinder Assembly Removal and Installation...................................................................................448 Clutch Operating Cylinder Assembly Inspection.................................................................................................449 Clutch Cover, Clutch Disc and Flywheel Components.............................................................................................449 Clutch Cover, Clutch Disc and Flywheel Removal and Installation...............................................................................450 Clutch Cover, Clutch Disc and Flywheel Inspection.............................................................................................451 Specifications....................................................................................................................................452 Tightening Torque Specifications..............................................................................................................452 Special Tools and Equipment.......................................................................................................................452 Recommended Service Material..................................................................................................................452 Special Tool..................................................................................................................................452 Steering..................................................................................................................................................453 Power Assisted Steering System........................................................................................................................455 Schematic and Routing Diagram.....................................................................................................................455 EPS System Wiring Circuit Diagram.............................................................................................................455 Diagnostic Information and Procedures.............................................................................................................456 Scan Tool Data................................................................................................................................456 Serial Data Link Circuit Check (No communication to P/S Control Module).......................................................................458 DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure...............................................................................460 DTC C1122: Engine Speed Signal Circuit Failure................................................................................................462 Inspection of P/S Control Module and Its Circuits.............................................................................................464 Repair Instructions...............................................................................................................................466 Motor Assembly Inspection.....................................................................................................................466 HVAC......................................................................................................................................................469 Precautions...........................................................................................................................................471 Precautions.......................................................................................................................................471 Precautions on HVAC...........................................................................................................................471 Heater and Ventilation................................................................................................................................472 General Description...............................................................................................................................472 Heater and Ventilation Construction...........................................................................................................472 Additional Heater System Description (If Equipped)............................................................................................473 Additional Heater System Components Location..................................................................................................473 Additional Heater System Electronic Input / Output Table (If Equipped)........................................................................474 On-Board Diagnostic System Description for Additional Heater System...........................................................................474 Schematic and Routing Diagram.....................................................................................................................475 Heater and Ventilation Wiring Circuit Diagram.................................................................................................475 Diagnostic Information and Procedures.............................................................................................................476 Heater and Ventilation Symptom Diagnosis......................................................................................................476 DTC Check for Additional Heater System........................................................................................................477 DTC Clearance for Additional Heater System....................................................................................................477 DTC Table for Additional Heater System........................................................................................................477 Scan Tool Data for Additional Heater System...................................................................................................478 Additional Heater System Check................................................................................................................478 Visual Inspection.............................................................................................................................480 DTC B1536: Additional Heater Relay No.1 Output Malfunction....................................................................................481 DTC B1537: Additional Heater Relay No.2 and No.3 Output Malfunction...........................................................................482 DTC B1541: Additional Heater Controller Back-Up Power Supply Malfunction......................................................................483 DTC B1551: Serial Communication Circuit Malfunction...........................................................................................484 DTC B1552: Serial Communication Data Malfunction..............................................................................................485 DTC B1553: CAN Communication Circuit Malfunction..............................................................................................485 DTC B1556: Engine Speed Data Malfunction......................................................................................................486 DTC B1557: Vehicle Speed Data Malfunction.....................................................................................................486 DTC B1559: Ignition Power Supply Voltage Data Malfunction.....................................................................................486 DTC B1561: Engine Coolant Temperature Data Malfunction........................................................................................487 DTC B1562: Outside Air Temperature Data Malfunction...........................................................................................487 DTC B1570: Engine Type Signal Failure.........................................................................................................488 DTC B1571: Combination Meter Spec Signal Failure..............................................................................................488 Inspection of Additional Heater Controller and Its Circuit (If Equipped)......................................................................489 Repair Instructions...............................................................................................................................490 HVAC Unit Components..........................................................................................................................490 Blower Motor Resistor Inspection..............................................................................................................490 Additional Heater Relay Inspection (If Equipped)..............................................................................................490 Additional Heater Assembly On-Vehicle Inspection (If Equipped)................................................................................491 Additional Heater Assembly Removal and Installation (If Equipped).............................................................................491 Additional Heater Controller Removal and Installation (If Equipped)...........................................................................492 Specifications....................................................................................................................................492 Tightening Torque Specifications..............................................................................................................492 Special Tools and Equipment.......................................................................................................................492 Special Tool..................................................................................................................................492 Air Conditioning System...............................................................................................................................493 Precautions.......................................................................................................................................493 Precautions on Servicing A/C System...........................................................................................................493 General Description...............................................................................................................................495 Refrigerant Type Identification...............................................................................................................495 Manual A/C Electronic Input Output Table......................................................................................................495 A/C Operation Description.....................................................................................................................495 Schematic and Routing Diagram.....................................................................................................................496 Major Components of A/C System................................................................................................................496 A/C System Wiring Diagram.....................................................................................................................497 Diagnostic Information and Procedures.............................................................................................................498 A/C System Symptom Diagnosis..................................................................................................................498 Abnormal Noise Symptom Diagnosis of A/C System................................................................................................500 A/C System Performance Inspection.............................................................................................................501 Repair Instructions...............................................................................................................................506 Operation Procedure for Refrigerant Charge....................................................................................................506 Condenser Cooling Fan Removal and Installation................................................................................................511 Condenser Cooling Fan Inspection..............................................................................................................511 Condenser Assembly Removal and Installation...................................................................................................511 HVAC Unit Components..........................................................................................................................512 A/C Refrigerant Pressure Sensor and Its Circuit Inspection....................................................................................514 A/C System Relay Inspection...................................................................................................................514 Compressor Assembly and Compressor Bracket Components.........................................................................................514 Compressor Assembly Removal and Installation..................................................................................................515 Compressor Drive Belt Inspection..............................................................................................................515 Compressor Drive Belt Removal and Installation................................................................................................515 Specifications....................................................................................................................................516 Tightening Torque Specifications..............................................................................................................516 Special Tools and Equipment.......................................................................................................................516 Recommended Service Material..................................................................................................................516 Special Tool..................................................................................................................................516 Body, Cab and Accessories.................................................................................................................................517 Wiring Systems........................................................................................................................................522 Harness Routing and Connector Layout Diagram......................................................................................................522 Engine Compartment............................................................................................................................522 Ground Point......................................................................................................................................535 Ground (earth) Point (Petrol, DSL 1.9L).......................................................................................................535 Ground (earth) Point (DSL 1.6L)...............................................................................................................536 Power Supply Diagram..............................................................................................................................537 Power Supply Diagram (DSL 1.9L)...............................................................................................................537 Power Supply Diagram (DSL 1.6L)...............................................................................................................538 Fuses in Main Fuse Box (DSL 1.9L/1.6L)........................................................................................................539 Individual Circuit Fuse Box No. 1 (DSL 1.9L)..................................................................................................540 Individual Circuit Fuse Box No. 1 (DSL 1.6L)..................................................................................................541 System Circuit Diagram............................................................................................................................542 System Circuit Diagram........................................................................................................................542 A-1 Cranking System Circuit Diagram (DSL 1.9L)................................................................................................543 A-1 Cranking System Circuit Diagram (DSL 1.6L)................................................................................................544 A-2 Charging System Circuit Diagram (DSL 1.9L)................................................................................................545 A-2 Charging System Circuit Diagram (DSL 1.6L)................................................................................................547 A-4 Cooling System Circuit Diagram (DSL 1.9L).................................................................................................548 A-4 Cooling System Circuit Diagram (DSL 1.6L).................................................................................................549 A-5 Engine and A/C Control System Circuit Diagram (DSL 1.9L)..................................................................................550 A-5 Engine and A/C Control System Circuit Diagram (DSL 1.6L)..................................................................................555 A-7 Immobilizer System Circuit Diagram (DSL 1.9L).............................................................................................560 A-7 Immobilizer System Circuit Diagram (DSL 1.6L).............................................................................................561 A-8 Body Control System Circuit Diagram (Petrol, DSL 1.9L)....................................................................................562 A-8 Body Control System Circuit Diagram (DSL 1.6L)............................................................................................566 D-7 Brake Light System Circuit Diagram (Petrol, DSL 1.9L).....................................................................................570 D-7 Brake Light System Circuit Diagram (DSL 1.6L).............................................................................................571 D-8 Back-Up Light System Circuit Diagram (Petrol, DSL 1.9L)...................................................................................572 D-8 Back-Up Light System Circuit Diagram (DSL 1.6L)...........................................................................................573 E-2 Auto A/C System Circuit Diagram (Petrol, DSL 1.9L)........................................................................................574 E-2 Auto A/C System Circuit Diagram (DSL 1.6L)................................................................................................576 E-3 PTC Heater Circuit Diagram (DSL 1.9L).....................................................................................................578 E-3 PTC Heater Circuit Diagram (DSL 1.6L).....................................................................................................580 F-2 Anti-Lock Brake System Circuit Diagram (Petrol, DSL 1.9L).................................................................................582 F-2 Anti-Lock Brake System Circuit Diagram (DSL 1.6L).........................................................................................584 F-3 Electronic Stability Program System Circuit Diagram (Petrol, DSL 1.9L)....................................................................586 F-3 Electronic Stability Program System Circuit Diagram (DSL 1.6L)............................................................................588 F-4 Power Steering System Circuit Diagram (Petrol, DSL 1.9L)..................................................................................590 F-4 Power Steering System Circuit Diagram (DSL 1.6L)..........................................................................................592 List of Connectors................................................................................................................................594 C Connector...................................................................................................................................594 D Connector (DSL).............................................................................................................................596 E Connector...................................................................................................................................597 Instrumentation / Driver Info. / Horn.................................................................................................................600 Precautions.......................................................................................................................................600 Precautions in Diagnosing Troubles for Combination Meter......................................................................................600 General Description...............................................................................................................................600 CAN Communication System Description..........................................................................................................600 Schematic and Routing Diagram.....................................................................................................................601 Combination Meter Circuit Diagram.............................................................................................................601 Diagnostic Information and Procedures.............................................................................................................603 Fuel Meter Symptom Diagnosis..................................................................................................................603 Low Fuel Warning Light Symptom Diagnosis......................................................................................................603 Oil Pressure Warning Light Symptom Diagnosis..................................................................................................603 Repair Instructions...............................................................................................................................604 Fuel Level Sensor Removal and Installation....................................................................................................604 Fuel Level Sensor Inspection..................................................................................................................604 Oil Pressure Switch Inspection................................................................................................................604 Engine Coolant Temperature (ECT) Sensor Inspection............................................................................................604 Seats.................................................................................................................................................605 Diagnostic Information and Procedures.............................................................................................................605 Front Seat Heater Symptom Diagnosis (If Equipped).............................................................................................605 Repair Instructions...............................................................................................................................605 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped).................................................................605 Front Seat Heater Wire Inspection (If Equipped)...............................................................................................605 Control Systems...........................................................................................................................................607 Body Electrical Control System........................................................................................................................609 General Description...............................................................................................................................609 CAN Communication System Description..........................................................................................................609 Schematic and Routing Diagram.....................................................................................................................609 Body Electrical Control System Wiring Circuit Diagram.........................................................................................609 Component Location................................................................................................................................612 BCM and Related System Component Location.....................................................................................................612 Diagnostic Information and Procedures.............................................................................................................613 BCM Self-Diagnosis Function...................................................................................................................613 Scan Tool Data................................................................................................................................614 DTC Table.....................................................................................................................................616 DTC U0073 (No. 0073): Control Module Communication Bus Off....................................................................................617 DTC U0100 (No. 0100): Lost Communication with ECM.............................................................................................617 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module...................................................617 Inspection of BCM and its Circuits............................................................................................................617 Immobilizer Control System............................................................................................................................626 Precautions.......................................................................................................................................626 Precautions in Diagnosing Troubles............................................................................................................626 Precaution in Replacing Immobilizer Control System............................................................................................626 Precautions in Handling Immobilizer Control System............................................................................................626 General Description...............................................................................................................................627 Immobilizer Control System Operation Description..............................................................................................627 Immobilizer Control System Components Description.............................................................................................627 On-Board Diagnostic System Description........................................................................................................628 Schematic and Routing Diagram.....................................................................................................................629 Immobilizer Control System Wiring Circuit Diagram.............................................................................................629 Diagnostic Information and Procedures.............................................................................................................630 Immobilizer Control System Check..............................................................................................................630 DTC Check.....................................................................................................................................630 DTC Clearance.................................................................................................................................630 DTC Table.....................................................................................................................................631 Scan Tool Data................................................................................................................................632 SVS Lamp Does Not Come ON with Ignition Switch ON and Engine Stop.............................................................................633 DTC B1000: Immobilizer Control Module Internal Failure........................................................................................634 DTC B3040: W-Line Communication Failure.......................................................................................................634 DTC B3042 / B3043: W-Line Circuit Malfunction Shorted to Ground / Shorted to Battery..........................................................635 DTC B3055: No Transponder.....................................................................................................................635 DTC B3056: No Fix Code Registered.............................................................................................................636 DTC B3057: No Password Registered.............................................................................................................636 DTC B3059: No Request from ECM................................................................................................................637 DTC B3060: Incorrect Transponder Detected.....................................................................................................637 DTC B3061: Transponder Communication Failure..................................................................................................638 DTC B3077: Read-Only Transponder Detected.....................................................................................................639 DTC P1610: Secret Key / Password Not Programed................................................................................................639 DTC P1611: Password Is Not Matched............................................................................................................639 DTC P1612 / P1613: No Signal from Immobilizer Control Module / Immobilizer System Malfunction.................................................640 DTC P1614: Incorrect Signal from Immobilizer Control Module...................................................................................640 Inspection of Immobilizer Control Module and Its Circuit......................................................................................641 Repair Instructions...............................................................................................................................642 Immobilizer Control Module Removal and Installation...........................................................................................642 How to Register Ignition Key..................................................................................................................642 Procedure after Immobilizer Control Module Replacement........................................................................................643 Procedure after ECM Replacement...............................................................................................................643 Registration Procedure of New Immobilizer Control System Components...........................................................................643 Special Tools and Equipment.......................................................................................................................643 Special Tool..................................................................................................................................643 COPYRIGHT ................................................................................................................................................644 BOOKCOVER ................................................................................................................................................645
S.S
