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Suzuki SX4 RW419D with D19AA Engine Supplementary Service Manual – PDF DOWNLOAD
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Suzuki SX4 RW419D with D19AA Engine Supplementary Service Manual – PDF DOWNLOAD
FILE DETAILS:
Suzuki SX4 RW419D with D19AA Engine Supplementary Service Manual – PDF DOWNLOAD
Language : English
Pages : 632
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Suzuki SX4 RW419D with D19AA Engine Supplementary Service Manual – PDF DOWNLOAD
IMPORTANT............................................................................................................................... 1 FOREWORD................................................................................................................................ 3 TABLE OF CONTENTS....................................................................................................................... 5 Precautions............................................................................................................................. 7 Precautions......................................................................................................................... 8 Precautions..................................................................................................................... 8 General Precautions......................................................................................................... 8 Precautions for Catalytic Converter and Diesel Particulate Filter........................................................... 10 General Information..................................................................................................................... 11 General Information................................................................................................................. 12 General Description............................................................................................................. 12 Engine Identification Number................................................................................................ 12 Component Location.............................................................................................................. 13 Warning, Caution and Information Labels Location............................................................................ 13 Maintenance and Lubrication......................................................................................................... 15 Scheduled Maintenance........................................................................................................... 15 Maintenance Schedule under Normal Driving Conditions........................................................................ 15 Maintenance Recommended under Severe Driving Conditions..................................................................... 16 Repair Instructions............................................................................................................. 17 Accessory Drive Belt Inspection............................................................................................. 17 Accessory Drive Belt Replacement............................................................................................ 17 Camshaft Timing Belt Replacement............................................................................................ 17 Valve Lash (Clearance) Inspection........................................................................................... 17 Engine Oil and Filter Change................................................................................................ 17 Engine Coolant Change....................................................................................................... 19 Air Cleaner Filter Inspection............................................................................................... 19 Air Cleaner Filter Replacement.............................................................................................. 19 Fuel Filter Replacement..................................................................................................... 19 Specifications.................................................................................................................. 19 Tightening Torque Specifications............................................................................................ 19 Special Tools and Equipment..................................................................................................... 20 Recommended Fluids and Lubricants........................................................................................... 20 Special Tool................................................................................................................ 20 Engine.................................................................................................................................. 21 Precautions......................................................................................................................... 26 Precautions..................................................................................................................... 26 Precautions for Engine...................................................................................................... 26 Engine General Information and Diagnosis............................................................................................ 27 Precautions..................................................................................................................... 27 Precautions on Engine Service............................................................................................... 27 Precautions in Diagnosing Trouble........................................................................................... 27 Statement on Cleanliness and Care........................................................................................... 27 General Description............................................................................................................. 28 Engine Diagnosis General Description........................................................................................ 28 OBD System Description...................................................................................................... 28 CAN Communication System Description........................................................................................ 29 Electronic Control System Description....................................................................................... 31 Diesel Particulate Filter Description....................................................................................... 36 Diesel Particulate Filter Regeneration Description.......................................................................... 36 Oil Life Monitoring System.................................................................................................. 37 Component Location.............................................................................................................. 38 Electronic Control System Components Location............................................................................... 38 Diagnostic Information and Procedures........................................................................................... 39 MIL Check................................................................................................................... 39 Engine and Emission Control System Check.................................................................................... 40 DTC Check................................................................................................................... 42 DTC Clearance............................................................................................................... 42 DTC Table................................................................................................................... 43 Fail-safe Table............................................................................................................. 47 Scan Tool Data.............................................................................................................. 50 Visual Inspection........................................................................................................... 54 Engine Basic Inspection..................................................................................................... 54 Engine Symptom Diagnosis.................................................................................................... 55 DTC P0016: Crankshaft Position - Camshaft Position Correlation.............................................................. 76 DTC P0045: Turbo Boost Control Solenoid Circuit / Open...................................................................... 77 DTC P0087 / P0088: Fuel Rail Pressure - Too Low / Too High.................................................................. 78 DTC P0090: Fuel Pressure Regulator Control Circuit.......................................................................... 79 DTC P0091: Fuel Pressure Regulator Control Circuit Low...................................................................... 80 DTC P0092: Fuel Pressure Regulator Control Circuit High..................................................................... 80 DTC P0093: Fuel System Leak Detected - Large Leak........................................................................... 81 DTC P0094: Fuel System Leak Detected - Small Leak........................................................................... 82 DTC P0095: Intake Air Temperature Sensor 2 Circuit.......................................................................... 82 DTC P0100 / P0101: Mass Air Flow Circuit / Mass Air Flow Circuit Range / Performance........................................ 83 DTC P010F: Mass Air Flow Sensitivity Drift.................................................................................. 83 DTC P0110 / P0111: Intake Air Temperature Sensor 1 Circuit / Intake Air Temperature Sensor 1 Circuit Range / Performance.... 84 DTC P0115: Engine Coolant Temperature Circuit............................................................................... 85 DTC P0116: Engine Coolant Temperature Circuit Range / Performance........................................................... 85 DTC P0120: Throttle Position Sensor Circuit................................................................................. 86 DTC P0122: Throttle Position Sensor Circuit Low............................................................................. 86 DTC P0168: Fuel Temperature Too High........................................................................................ 87 DTC P0180: Fuel Temperature Sensor Circuit.................................................................................. 88 DTC P0190: Fuel Rail Pressure Sensor Circuit................................................................................ 88 DTC P0201 / P0202 / P0203 / P0204: Injector Circuit/Open - Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4................ 88 DTC P0216: Injector / Injection Timing Control Circuit...................................................................... 89 DTC P0219: Engine Overspeed Condition....................................................................................... 89 DTC P0220: Pedal Position Sensor Circuit.................................................................................... 89 DTC P0230: Fuel Pump Primary Circuit........................................................................................ 90 DTC P0235: Turbo Boost Sensor Circuit....................................................................................... 90 DTC P0237 / P0238: Turbo Boost Sensor Circuit Low / High.................................................................... 91 DTC P0262 / P0265 / P0268 / P0271: Cylinder 1 / 2 / 3 / 4 Injector Circuit High............................................. 93 DTC P0335: Crankshaft Position Sensor Circuit............................................................................... 93 DTC P0340: Camshaft Position Sensor Circuit................................................................................. 93 DTC P0380: Glow Plug Circuit................................................................................................ 94 DTC P0401: Exhaust Gas Recirculation Flow Insufficient Detected............................................................. 94 DTC P0402: Exhaust Gas Recirculation Flow Excessive Detected................................................................ 95 DTC P0403: Exhaust Gas Recirculation Control Circuit........................................................................ 96 DTC P0480: Fan 1 Control Circuit............................................................................................ 96 DTC P0481: Fan 2 Control Circuit............................................................................................ 97 DTC P0482: Fan 3 Control Circuit............................................................................................ 98 DTC P0500: Vehicle Speed Sensor............................................................................................. 99 DTC P0503: Vehicle Speed Sensor Intermittent / Erratic / High...............................................................100 DTC P0504: Brake Switch 1 / 2 Correlation...................................................................................100 DTC P0520: Engine Oil Pressure Switch Circuit...............................................................................101 DTC P0530: A/C Refrigerant Pressure Sensor Circuit..........................................................................102 DTC P0560: System Voltage...................................................................................................102 DTC P0601: Internal Control Module Memory Check Sum Error...................................................................102 DTC P0606: ECM Processor....................................................................................................103 DTC P060A: Shut Off Monitoring During Initialization........................................................................103 DTC P060B: ADC Monitoring...................................................................................................103 DTC P0611: ECM Performance..................................................................................................104 DTC P061B: FMTC Map Non Strictly Monotonus..................................................................................104 DTC P061C: Engine Speed Calculation in Overrun..............................................................................104 DTC P062D: Injectors Specific Chip 1........................................................................................104 DTC P062E: Injectors Specific Chip 2........................................................................................105 DTC P0638: Throttle Actuator Control Range / Performance....................................................................105 DTC P0641: Sensor Reference Voltage 1 Circuit / Open........................................................................106 DTC P0645: A/C Clutch Relay Control Circuit.................................................................................106 DTC P0651: Sensor Reference Voltage 2 Circuit / Open........................................................................107 DTC P0683: Glow Plug Control Module to ECM Communication Circuit............................................................107 DTC P0685: ECM Power Relay Control Circuit / Open...........................................................................108 DTC P0697: Sensor Reference Voltage 3 Circuit / Open........................................................................108 DTC P0704: Clutch Switch Input Circuit Malfunction..........................................................................108 DTC P0748: Fuel Flow Actuator Circuit.......................................................................................109 DTC P0778: Fuel Pressure Regulator Circuit..................................................................................110 DTC P1205: Diesel Particulate Filter Flow Resistance Monitoring Too Low.....................................................110 DTC P1206: Diesel Particulate Filter Flow Resistance Monitoring Too High....................................................111 DTC P1218: Hard Ware Recovery...............................................................................................111 DTC P1219: Diesel Particulate Filter Regeneration Not Ended.................................................................112 DTC P1301: Fuel Injector Calibration Code Classification....................................................................112 DTC P1605: Communication between CY310 and mP...............................................................................112 DTC P1606: Hard Ware Module Communication...................................................................................113 DTC P1618: Supply Voltage of CJ940 above Limit..............................................................................113 DTC P1619: Supply Voltage of CJ940 below Limit..............................................................................113 DTC P1623: SPI Communication................................................................................................114 DTC P1667: Fuel Filter Heating..............................................................................................114 DTC P2080 / P2081: Exhaust Gas Temperature Sensor Circuit Range / Performance / Intermittent................................114 DTC P2084 / P2085: Exhaust Gas Temperature Sensor-2 Circuit Range / Performance / Intermittent..............................115 DTC P2100 / P2101: Throttle Actuator Control Motor Circuit / Open / Range / Performance.....................................115 DTC P2107 / P2108: Throttle Actuator Control Module Processor / Performance.................................................116 DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Stuck Closed.............................................116 DTC P2135: Throttle / Pedal Position Sensor Voltage Correlation.............................................................116 DTC P2146 / P2148: Fuel Injector Group 1 Supply Voltage Circuit / Open / High...............................................117 DTC P2149 / P2151: Fuel Injector Group 2 Supply Voltage Circuit / Open / High...............................................117 DTC P2226: Barometric Pressure Circuit......................................................................................117 DTC P2264: Water in Fuel Sensor Circuit.....................................................................................117 DTC P2293: Fuel Pressure Regulator Performance..............................................................................118 DTC P2294: Fuel Pressure Regulator Control Circuit..........................................................................119 DTC P2295: Fuel Pressure Regulator Control Circuit Low......................................................................119 DTC P2296: Fuel Pressure Regulator Control Circuit High.....................................................................120 DTC P2299: Brake Pedal Position / Accelerator Pedal Position Incompatible...................................................121 DTC P2452: Differential Pressure Sensor Electrical Failure..................................................................121 DTC P2453 / P2455: Differential Pressure Sensor Hose Line Monitoring / Plausibility.........................................122 DTC P2505: ECM Power Input Signal...........................................................................................122 DTC P2620: Throttle Position Output Circuit / Open..........................................................................122 DTC U1601: Control Module Communication Bus Off.............................................................................123 DTC U1700: Lost Communication with Body Control Module......................................................................124 DTC U1706: Lost Communication with ABS or ESP‚ Control Module...............................................................125 DTC U1711: Lost Communication with 4WD Control Module.......................................................................126 Table - 1040AA: Check on Supply Voltage and Current Uptake..................................................................128 Table - 1040OA: Fuel Supply System Check....................................................................................128 Table - 1048OA: Air Intake / Vacuum Circuit Check...........................................................................130 Table - 1060EA: Fuel Temperature Sensor Check...............................................................................131 Table - 1060FA: Injector Operation Check....................................................................................132 Table - 1060FB: Injector Circuit Operation Check............................................................................134 Table - 1060GD: Barometric Pressure Check...................................................................................137 Table - 1060GF: Boost Pressure Check........................................................................................137 Table - 1060GG: Check Measured Air Mass.....................................................................................138 Table - 1060GH: Diesel Fuel Pressure Check..................................................................................139 Table - 1060GI: Engine Speed Check..........................................................................................140 Table - 1060GL: Main Relay Operation Check..................................................................................141 Table - 1060GM: Sensor Power Supply 1 Circuit Check.........................................................................142 Table - 1060GN: Sensor Power Supply 2 Circuit Check.........................................................................143 Table - 1060GO: Inlet Throttle Valve Operation Check........................................................................145 Table - 1060GP: Sensor Power Supply 3 Circuit Check.........................................................................146 Table - 1060GQ: Fuel Filter Water Detection Sensor Operation Check..........................................................147 Table - 1060GR: Fuel Pressure Regulator Operation Check.....................................................................148 Table - 1060GS: MAF Sensor Operation Check..................................................................................148 Table - 1060OE: ECT Sensor Operation Check..................................................................................149 Table - 1064BB: Boost Pressure Control Solenoid Valve Operation Check.......................................................150 Table - 1064BD: IAT Sensor 2 Check..........................................................................................150 Table - 1068AC: Accelerator Pedal Check.....................................................................................151 Table - 1080BE: Particulate Filter Saturation Check.........................................................................153 Table - 1080BF: Differential Pressure Sensor Operation Check................................................................154 Table - 1080BG: Exhaust Gas Temperature Sensor-1 Operation Check............................................................155 Table - 1080BH: Exhaust Gas Temperature Sensor-2 Operation Check............................................................155 Table - 1080CB: EGR Valve Operation Check...................................................................................156 Table - 3340AB: Speed Signal Check..........................................................................................157 Table - 5505AC: Fuel Heater Operation Check.................................................................................157 Table - 5510CG: CMP Sensor Operation Check..................................................................................158 Table - 5520CA: Glow Plugs Operation Check..................................................................................159 Table - 5530BB: Battery Voltage Check.......................................................................................160 Low Fuel Pressure Circuit Check.............................................................................................161 High Fuel Pressure Circuit Check............................................................................................163 Special Tools and Equipment.....................................................................................................164 Special Tool................................................................................................................164 Aux. Emission Control Devices.......................................................................................................165 Repair Instructions.............................................................................................................165 EGR Valve Inspection........................................................................................................165 Exhaust Gas Temperature Sensor 1 and 2 Removal and Installation.............................................................165 Exhaust Gas Temperature Sensor 1 and 2 Inspection...........................................................................165 Differential Pressure Sensor Removal and Installation.......................................................................165 Engine Electrical Devices...........................................................................................................166 Precautions.....................................................................................................................166 Precaution in Replacing ECM.................................................................................................166 General Description.............................................................................................................166 ECM Registration............................................................................................................166 Repair Instructions.............................................................................................................167 Idle Speed Inspection.......................................................................................................167 Engine Control Module (ECM) Removal and Installation........................................................................167 Registration for ECM Replacement............................................................................................167 Fuel Injector Registration..................................................................................................168 Fuel Pressure Sensor Data Initialization....................................................................................168 Diesel Particulate Filter Data Initialization...............................................................................168 Differential Pressure Sensor Data Initialization............................................................................168 Pre-catalytic Converter Data Initialization.................................................................................168 Diesel Particulate Filter After-sales Regeneration..........................................................................168 After-sales Regeneration Failure............................................................................................169 Glow Plug Removal and Installation..........................................................................................170 Glow Plug Inspection........................................................................................................170 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection......................................................171 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation...................................................171 Accelerator Pedal Position (APP) Sensor Assembly Inspection.................................................................171 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................172 Camshaft Position (CMP) Sensor Removal and Installation.....................................................................173 CKP Sensor Removal and Installation.........................................................................................173 CKP Sensor Inspection.......................................................................................................174 Boost Pressure Sensor with IAT Sensor-2 Removal and Installation............................................................174 Fuel Pump Relay, Starting Motor Control Relay, Main Relay and Fuel Heating Relay Inspection.................................174 Glow Plug Control Module Removal and Installation...........................................................................175 Boost Pressure Control Solenoid Valve Removal and Installation..............................................................175 Boost Pressure Control Solenoid Valve Inspection............................................................................175 MAF Sensor with IAT Sensor-1 Removal and Installation.......................................................................175 Inlet Throttle Valve Removal and Installation...............................................................................175 Inlet Throttle Valve On-Vehicle Inspection..................................................................................175 Specifications..................................................................................................................176 Tightening Torque Specifications............................................................................................176 Engine Mechanical...................................................................................................................177 Diagnostic Information and Procedures...........................................................................................177 Compression Check...........................................................................................................177 Vacuum Pump Inspection......................................................................................................178 Valve Lash (Clearance) Inspection...........................................................................................178 Valve Lash (Clearance) Adjustment...........................................................................................178 Repair Instructions.............................................................................................................180 Air Cleaner Components......................................................................................................180 Air Cleaner Filter Removal and Installation.................................................................................181 Air Cleaner Filter Inspection and Cleaning..................................................................................181 Intercooler Components......................................................................................................182 Intercooler Removal and Installation........................................................................................183 Cylinder Head Cover Components..............................................................................................183 Cylinder Head Cover Removal and Installation................................................................................184 Inlet Throttle Valve Removal and Installation...............................................................................185 Vacuum Pump Removal and Installation........................................................................................186 EGR Valve Components........................................................................................................187 EGR Valve Removal and Installation..........................................................................................188 EGR Pipe and EGR Cooler Removal and Installation............................................................................188 Turbocharger Included in Exhaust Manifold Components........................................................................190 Turbocharger Included in Exhaust Manifold Removal and Installation..........................................................190 Turbocharger Included in Exhaust Manifold Inspection........................................................................193 Timing Belt and Belt Tensioner Components...................................................................................194 Timing Belt, Belt tensioner and Idler Removal and Installation..............................................................194 Timing Belt Inspection......................................................................................................198 Intake Manifold Components..................................................................................................199 Intake Manifold Removal and Installation....................................................................................200 Camshaft and Tappet Components..............................................................................................201 Camshaft and Tappet Removal and Installation................................................................................201 Camshaft and Tappet Inspection..............................................................................................204 Valve and Cylinder Head Assembly Components.................................................................................207 Valve and Cylinder Head Assembly Removal and Installation...................................................................208 Valve and Cylinder Head Assembly Inspection.................................................................................210 Valve and Cylinder Head Disassembly and Reassembly..........................................................................210 Valves and Valve Guides Inspection..........................................................................................212 Cylinder Head Inspection....................................................................................................213 Valve Spring Inspection.....................................................................................................214 Engine Mounting Components..................................................................................................215 Engine Assembly Removal and Installation....................................................................................216 Piston, Piston Ring, Connecting Rod and Cylinder Components.................................................................219 Piston, Piston Ring and Connecting Rod Removal and Installation.............................................................220 Cylinders, Pistons and Piston Rings Inspection..............................................................................222 Piston Pins and Connecting Rods Inspection..................................................................................224 Crank Pin and Connecting Rod Bearings Inspection............................................................................224 Main Bearing, Crankshaft and Cylinder Block Components......................................................................227 Main Bearing, Crankshaft and Cylinder Block Removal and Installation........................................................228 Crankshaft Inspection.......................................................................................................231 Main Bearings Inspection....................................................................................................231 Cylinder Block Inspection...................................................................................................233 Specifications..................................................................................................................234 Tightening Torque Specifications............................................................................................234 Special Tools and Equipment.....................................................................................................236 Recommended Service Material................................................................................................236 Special Tool................................................................................................................236 Engine Lubrication System...........................................................................................................238 General Description.............................................................................................................238 Engine Lubrication Description..............................................................................................238 Diagnostic Information and Procedures...........................................................................................238 Oil Pressure Check..........................................................................................................238 Repair Instructions.............................................................................................................239 Oil Pan and Oil Pump Strainer Components....................................................................................239 Oil Pan and Oil Pump Strainer Removal and Installation......................................................................240 Oil Pump Component..........................................................................................................242 Oil Pump Removal and Installation...........................................................................................243 Oil Pump Disassembly and Reassembly.........................................................................................245 Oil Pump Inspection.........................................................................................................245 Heat Exchanger Removal and Installation.....................................................................................246 Heat Exchanger Disassembly and Reassembly...................................................................................246 Specifications..................................................................................................................247 Tightening Torque Specifications............................................................................................247 Special Tools and Equipment.....................................................................................................248 Recommended Service Material................................................................................................248 Special Tool................................................................................................................248 Engine Cooling System...............................................................................................................249 General Description.............................................................................................................249 Cooling System Description..................................................................................................249 Coolant Description.........................................................................................................249 Schematic and Routing Diagram...................................................................................................250 Coolant Circulation.........................................................................................................250 Diagnostic Information and Procedures...........................................................................................250 Engine Cooling Symptom Diagnosis............................................................................................250 Repair Instructions.............................................................................................................251 Cooling System Components...................................................................................................251 Coolant Level Check.........................................................................................................252 Engine Cooling System Inspection and Cleaning...............................................................................252 Cooling System Draining.....................................................................................................253 Cooling System Refilling....................................................................................................253 Cooling System Flushing.....................................................................................................254 Cooling Water Pipe or Hose Removal and Installation.........................................................................254 Radiator Cooling Fan Motor On-Vehicle Inspection............................................................................254 Radiator Cooling Fan Relay Inspection.......................................................................................255 Radiator Cooling Fan Assembly Removal and Installation......................................................................255 Radiator Cooling Fan Disassembly and Reassembly.............................................................................255 Radiator Cooling Sub Fan Removal and Installation...........................................................................256 Radiator Cooling Sub Fan Inspection.........................................................................................256 Radiator On-Vehicle Inspection and Cleaning.................................................................................256 Radiator Removal and Installation...........................................................................................257 Water Pump Removal and Installation.........................................................................................257 Water Pump Inspection.......................................................................................................257 Thermostat Removal and Installation.........................................................................................258 Specifications..................................................................................................................258 Tightening Torque Specifications............................................................................................258 Fuel System.........................................................................................................................259 Precautions.....................................................................................................................259 Precautions on Fuel System Service..........................................................................................259 Fuel System Description.....................................................................................................262 Repair Instructions.............................................................................................................263 Fuel System Components......................................................................................................263 Fuel Pressure Relief Procedure..............................................................................................265 Fuel Leakage Check Procedure................................................................................................265 Water Draining of Fuel Filter...............................................................................................265 Air Bleeding of Fuel System.................................................................................................265 Fuel Filter Assembly Removal and Installation...............................................................................266 Fuel Heater and Fuel Temperature Sensor Inspection..........................................................................266 Fuel Filter Element Replacement.............................................................................................267 Fuel Hose Disconnecting and Reconnecting....................................................................................268 Fuel Lines Inspection.......................................................................................................270 Fuel Pipe Removal and Installation..........................................................................................270 High Pressure Pipe Removal and Installation.................................................................................271 Fuel Injector On-Vehicle Inspection.........................................................................................272 Fuel Injector Removal and Installation......................................................................................272 High Pressure Pump Removal and Installation.................................................................................274 Fuel Flow Actuator Inspection...............................................................................................277 Common Rail, Fuel Pressure Sensor and Fuel Pressure Regulator Valve Removal and Installation................................277 Fuel Pressure Regulator Valve Inspection....................................................................................278 Fuel Pressure Sensor Inspection.............................................................................................278 Fuel Damper Removal and Installation........................................................................................278 Fuel Filler Cap Inspection..................................................................................................279 Fuel Tank Removal and Installation..........................................................................................279 Fuel Tank Inspection........................................................................................................281 Fuel Tank Purging Procedure.................................................................................................281 Fuel Pump Assembly Removal and Installation.................................................................................281 Fuel Pump Inspection........................................................................................................282 Specifications..................................................................................................................283 Tightening Torque Specifications............................................................................................283 Special Tools and Equipment.....................................................................................................284 Special Tool................................................................................................................284 Starting System.....................................................................................................................285 Diagnostic Information and Procedures...........................................................................................285 Cranking System Test........................................................................................................285 Repair Instructions.............................................................................................................286 Starting Motor Unit Components..............................................................................................286 Starting Motor Dismounting and Remounting...................................................................................286 Specifications..................................................................................................................287 Tightening Torque Specifications............................................................................................287 Charging System.....................................................................................................................288 Diagnostic Information and Procedures...........................................................................................288 Generator Symptom Diagnosis.................................................................................................288 Generator Test (Undercharged Battery Check).................................................................................288 Generator Test (Overcharged Battery Check)..................................................................................289 Repair Instructions.............................................................................................................289 Generator Unit Components...................................................................................................289 Generator Drive Belt, Tensioner and Idler Pulley Removal and Installation...................................................290 Generator Drive Belt Inspection.............................................................................................290 Specifications..................................................................................................................290 Tightening Torque Specifications............................................................................................290 Exhaust System......................................................................................................................291 General Description.............................................................................................................291 Exhaust System Description..................................................................................................291 Diesel Particulate Filter...................................................................................................291 Diagnostic Information and Procedures...........................................................................................291 Exhaust System Check........................................................................................................291 Repair Instructions.............................................................................................................292 Exhaust System Components...................................................................................................292 Exhaust Manifold Removal and Installation...................................................................................292 Pre-Catalytic Converter Removal and Installation............................................................................293 Diesel Particulate Filter (with Main Catalytic Converter) Removal and Installation..........................................293 Specifications..................................................................................................................294 Tightening Torque Specifications............................................................................................294 Driveline / Axle........................................................................................................................295 Drive Shaft / Axle..................................................................................................................297 Front...........................................................................................................................297 Component Location..........................................................................................................297 Front Drive Shaft Assembly Components Location..........................................................................297 Repair Instructions.........................................................................................................298 Front Drive Shaft Components............................................................................................298 Front Drive Shaft Assembly Removal and Installation.....................................................................299 Front Drive Shaft Disassembly and Reassembly............................................................................300 Center Shaft and Center Bearing Support Disassembly and Assembly........................................................304 Specifications..............................................................................................................305 Tightening Torque Specifications........................................................................................305 Special Tools and Equipment.................................................................................................305 Recommended Service Material............................................................................................305 Special Tool............................................................................................................305 Rear............................................................................................................................306 Repair Instructions.........................................................................................................306 Rear Drive Shaft Disassembly and Reassembly.............................................................................306 Special Tools and Equipment.................................................................................................307 Special Tool............................................................................................................307 Differential........................................................................................................................308 General Description.............................................................................................................308 CAN Communication System Description........................................................................................308 Diagnostic Information and Procedures...........................................................................................308 DTC Table...................................................................................................................308 DTC U0100: Lost Communication with ECM......................................................................................309 DTC U0121: Lost Communication with ABS Control Module.......................................................................310 Repair Instructions.............................................................................................................311 Rear Differential Mountings Components......................................................................................311 Specifications..................................................................................................................311 Tightening Torque Specifications............................................................................................311 Transmission / Transaxle................................................................................................................313 Manual Transmission/Transaxle.......................................................................................................314 General Description.............................................................................................................314 Manual Transaxle Construction...............................................................................................314 Repair Instructions.............................................................................................................318 Manual Transaxle Oil Level Check............................................................................................318 Manual Transaxle Oil Change.................................................................................................318 Differential Side Oil Seal Replacement......................................................................................319 Gear Shift Control Lever and Cable Components...............................................................................320 Gear Shift Control Lever and Cable Removal and Installation.................................................................321 Gear Select Control Cable Adjustment........................................................................................321 Back Up Lamp Switch Removal and Installation................................................................................322 Manual Transaxle Unit Components............................................................................................323 Manual Transaxle Unit Dismounting and Remounting............................................................................324 Gear Shift and Select Shaft Assembly Components.............................................................................325 Gear Shift and Select Shaft Assembly Removal and Installation...............................................................325 Gear Shift and Select Shaft Assembly Disassembly and Reassembly.............................................................326 Manual Transaxle Assembly Components........................................................................................327 Manual Transaxle Assembly Disassembly and Reassembly........................................................................328 Right Case Disassembly and Reassembly.......................................................................................331 Left Case Disassembly and Reassembly........................................................................................332 Input Shaft and Countershaft and Reverse Gears Components...................................................................334 Input Shaft Disassembly and Reassembly......................................................................................335 Countershaft Disassembly and Reassembly.....................................................................................339 Gear Shift Shaft Components.................................................................................................343 Gear Shift Shaft and Fork Inspection........................................................................................344 Differential Components.....................................................................................................344 Differential Disassembly and Reassembly.....................................................................................344 Specifications..................................................................................................................346 Tightening Torque Specifications............................................................................................346 Special Tools and Equipment.....................................................................................................347 Recommended Service Material................................................................................................347 Special Tool................................................................................................................347 Clutch..............................................................................................................................349 General Description.............................................................................................................349 Clutch (Hydraulic Type) Construction........................................................................................349 Repair Instructions.............................................................................................................350 Clutch Pedal Position (CPP) Switch Removal and Installation.................................................................350 Clutch Pedal Position (CPP) Switch Inspection...............................................................................350 Clutch Pedal Inspection.....................................................................................................350 Air Bleeding of Clutch System...............................................................................................351 Clutch Fluid Pipe Removal and Installation..................................................................................351 Clutch Operating Cylinder Assembly Removal and Installation.................................................................352 Clutch Cover and Clutch Disc Components.....................................................................................353 Clutch Cover and Clutch Disc Removal and Installation.......................................................................354 Specifications..................................................................................................................355 Tightening Torque Specifications............................................................................................355 Special Tools and Equipment.....................................................................................................355 Recommended Service Material................................................................................................355 Special Tool................................................................................................................355 Steering................................................................................................................................357 Power Assisted Steering System......................................................................................................359 Diagnostic Information and Procedures...........................................................................................359 DTC C1122: Engine Speed Signal Circuit Failure..............................................................................359 DTC C1155: P/S Control Module Failure.......................................................................................360 Inspection of P/S Control Module and Its Circuits...........................................................................361 Repair Instructions.............................................................................................................363 Motor Assembly Inspection...................................................................................................363 HVAC....................................................................................................................................365 Heater and Ventilation..............................................................................................................368 General Description.............................................................................................................368 Heater and Ventilation Construction.........................................................................................368 Additional Heater System Description (If Equipped)..........................................................................369 Additional Heater System Components Location................................................................................369 Additional Heater System Electronic Input / Output Table (If Equipped)......................................................370 On-Board Diagnostic System Description for Additional Heater System.........................................................370 Schematic and Routing Diagram...................................................................................................371 Heater and Ventilation Wiring Circuit Diagram...............................................................................371 Diagnostic Information and Procedures...........................................................................................372 Heater and Ventilation Symptom Diagnosis....................................................................................372 DTC Check for Additional Heater System......................................................................................373 DTC Clearance for Additional Heater System..................................................................................373 DTC Table for Additional Heater System......................................................................................374 Scan Tool Data for Additional Heater System.................................................................................374 Additional Heater System Check..............................................................................................375 Visual Inspection...........................................................................................................377 DTC B1536: Additional Heater Relay No.1 Output Malfunction..................................................................377 DTC B1537: Additional Heater Relay No.2 and No.3 Output Malfunction.........................................................378 DTC B1541: Additional Heater Controller Back-Up Power Supply Malfunction....................................................379 DTC B1551: Serial Communication Circuit Malfunction.........................................................................380 DTC B1552: Serial Communication Data Malfunction............................................................................380 DTC B1553: CAN Communication Circuit Malfunction............................................................................381 DTC B1556: Engine Speed Data Malfunction....................................................................................381 DTC B1557: Vehicle Speed Data Malfunction...................................................................................382 DTC B1559: Ignition Power Supply Voltage Data Malfunction...................................................................382 DTC B1561: Engine Coolant Temperature Data Malfunction......................................................................382 DTC B1562: Outside Air Temperature Data Malfunction.........................................................................383 Inspection of Additional Heater Controller and Its Circuit (If Equipped)....................................................383 Repair Instructions.............................................................................................................385 HVAC Unit Components........................................................................................................385 HVAC Unit Removal and Installation..........................................................................................385 Blower Motor Removal and Installation.......................................................................................385 Blower Motor Inspection.....................................................................................................385 Blower Motor Resistor Inspection............................................................................................386 Additional Heater Relay Inspection (If Equipped)............................................................................386 Additional Heater Assembly On-Vehicle Inspection (If Equipped)..............................................................386 Additional Heater Assembly Removal and Installation (If Equipped)...........................................................387 Additional Heater Controller Removal and Installation (If Equipped).........................................................387 Specifications..................................................................................................................388 Tightening Torque Specifications............................................................................................388 Special Tools and Equipment.....................................................................................................388 Special Tool................................................................................................................388 Air Conditioning System.............................................................................................................389 Manual Type.....................................................................................................................389 Precautions.................................................................................................................389 Precautions on Servicing A/C System.....................................................................................389 General Description.........................................................................................................390 Refrigerant Type Identification.........................................................................................390 Sub-Cool A/C System Description.........................................................................................391 Manual A/C Electronic Input Output Table................................................................................392 A/C Operation Description...............................................................................................392 Schematic and Routing Diagram...............................................................................................393 Major Components of A/C System..........................................................................................393 A/C System Wiring Diagram...............................................................................................394 Diagnostic Information and Procedures.......................................................................................395 A/C System Symptom Diagnosis............................................................................................395 Abnormal Noise Symptom Diagnosis of A/C System..........................................................................397 A/C System Performance Inspection.......................................................................................398 Repair Instructions.........................................................................................................403 Operation Procedure for Refrigerant Charge..............................................................................403 Condenser Cooling Fan Removal and Installation..........................................................................409 Condenser Cooling Fan Inspection........................................................................................409 Condenser Assembly Removal and Installation.............................................................................410 HVAC Unit Components....................................................................................................411 HVAC Unit Removal and Installation......................................................................................412 A/C Refrigerant Pressure Sensor and Its Circuit Inspection..............................................................412 A/C System Relay Inspection.............................................................................................413 Compressor Assembly and Compressor Bracket Components...................................................................413 Compressor Pulley Inspection............................................................................................414 Compressor ON/OFF Valve On-Vehicle Inspection...........................................................................414 Compressor Drive Belt Inspection........................................................................................414 Compressor Drive Belt Removal and Installation..........................................................................414 Compressor Assembly Removal and Installation............................................................................414 Specifications..............................................................................................................415 Tightening Torque Specifications........................................................................................415 Special Tools and Equipment.................................................................................................415 Recommended Service Material............................................................................................415 Special Tool............................................................................................................415 Automatic Type..................................................................................................................416 General Description.........................................................................................................416 Auto A/C System Description.............................................................................................416 Schematic and Routing Diagram...............................................................................................418 A/C System Wiring Diagram...............................................................................................418 Diagnostic Information and Procedures.......................................................................................419 A/C System Symptom Diagnosis............................................................................................419 DTC Table...............................................................................................................422 Fail-Safe Table.........................................................................................................425 Scan Tool Data..........................................................................................................425 Visual Inspection.......................................................................................................427 DTC B1551: Serial Communication Circuit Malfunction.....................................................................427 DTC B1557: VSS Signal Failure...........................................................................................428 Inspection of HVAC Control Module and Its Circuit.......................................................................429 Repair Instructions.........................................................................................................431 HVAC Unit Components....................................................................................................431 Evaporator Temperature Sensor Removal and Installation..................................................................433 Evaporator Temperature Sensor Inspection................................................................................433 Compressor Drive Belt Inspection........................................................................................434 Compressor Assembly and Compressor Bracket Components...................................................................434 Compressor Pully Inspection.............................................................................................434 Compressor ON/OFF Valve On-Vehicle Inspection...........................................................................434 Body, Cab and Accessories...............................................................................................................435 Wiring Systems......................................................................................................................440 Precautions.....................................................................................................................440 Cautions in Body Electrical System Servicing................................................................................440 Precautions for Wiring System...............................................................................................440 General Description.............................................................................................................441 Abbreviations...............................................................................................................441 Wire / Connector Color Symbols..............................................................................................441 Symbols and Marks...........................................................................................................442 How to Read Connector Layout Diagram........................................................................................444 How to Read Connector Codes and Terminal Nos................................................................................445 How to Read Ground Point....................................................................................................447 How to Read Power Supply Diagram............................................................................................448 How to Read System Circuit Diagram..........................................................................................448 Harness Routing and Connector Layout Diagram....................................................................................450 Connector Layout Diagram....................................................................................................450 Engine Compartment..........................................................................................................450 Instrument Panel............................................................................................................458 Door, Roof..................................................................................................................463 Floor.......................................................................................................................466 Rear........................................................................................................................470 Ground Point....................................................................................................................471 Ground (earth) Point........................................................................................................471 Power Supply Diagram............................................................................................................472 Power Supply Diagram (Petrol)...............................................................................................472 Power Supply Diagram (DSL)..................................................................................................473 Fuses and the Protected Parts...............................................................................................474 Fuses in Main Fuse Box (Petrol).............................................................................................474 Fuses in Main Fuse Box (DSL)................................................................................................474 Individual Circuit Fuse Box No. 1 (Petrol)..................................................................................475 Individual Circuit Fuse Box No. 1 (DSL).....................................................................................476 Individual Circuit Fuse Box No. 3 (DSL).....................................................................................477 Individual Circuit Fuse Box No. 2 (In J/B)..................................................................................478 Junction Block (J/B) Connector / Fuse Layout................................................................................480 Junction Block Inner Circuit (Overview).....................................................................................482 Junction Block Inner Circuit (Detail).......................................................................................483 System Circuit Diagram..........................................................................................................488 System Circuit Diagram......................................................................................................488 A-1 Cranking System Circuit Diagram (Petrol)................................................................................489 A-1 Cranking System Circuit Diagram (DSL)...................................................................................490 A-2 Charging System Circuit Diagram (Petrol)................................................................................491 A-2 Charging System Circuit Diagram (DSL)...................................................................................492 A-3 Ignition System Circuit Diagram (Petrol)................................................................................493 A-4 Cooling System Circuit Diagram (Petrol).................................................................................494 A-4 Cooling System Circuit Diagram (DSL)....................................................................................495 A-5 Engine and A/C Control System Circuit Diagram (Petrol)..................................................................496 A-5 Engine and A/C Control System Circuit Diagram (DSL).....................................................................501 A-6 A/T Control System Circuit Diagram......................................................................................506 A-7 Immobilizer System Circuit Diagram (Petrol).............................................................................508 A-7 Immobilizer System Circuit Diagram (DSL)................................................................................509 A-8 Body Control System Circuit Diagram.....................................................................................510 A-10 4WD Control System.....................................................................................................514 B-1 Windshield Wiper and Washer Circuit Diagram.............................................................................515 B-2 Rear Wiper and Washer Circuit Diagram...................................................................................516 B-3 Rear Defogger Circuit Diagram...........................................................................................517 B-4 Power Window Circuit Diagram............................................................................................518 B-5 Power Door Lock Circuit Diagram.........................................................................................520 B-6 Power Mirror Circuit Diagram............................................................................................522 B-7 Horn Circuit Diagram....................................................................................................523 B-8 Seat Heater Circuit Diagram.............................................................................................524 B-9 Keyless Start System Circuit Diagram....................................................................................525 C-1 Combination Meter Circuit Diagram (Meter)...............................................................................526 C-2 Combination Meter Circuit Diagram (Indicator)...........................................................................527 C-3 Combination Meter Circuit Diagram (Warning Light).......................................................................528 D-1 Headlight System Circuit Diagram........................................................................................530 D-2 Position, Tail and Licence Plate Light System Circuit Diagram...........................................................532 D-3 Front Fog Light System Circuit Diagram..................................................................................533 D-4 Illumination Light System Circuit Diagram...............................................................................534 D-5 Interior Light System Circuit Diagram...................................................................................535 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram.............................................................536 D-7 Brake Light System Circuit Diagram......................................................................................538 D-8 Back-Up Light System Circuit Diagram....................................................................................539 D-9 Headlight Beam Leveling System Circuit Diagram..........................................................................540 D-10 Rear Fog Light Circuit Diagram.........................................................................................541 E-1 Heater System Circuit Diagram...........................................................................................542 E-2 Auto A/C System Circuit Diagram.........................................................................................544 E-3 PTC Heater Circuit Diagram (DSL)........................................................................................546 F-1 Air-Bag System Circuit Diagram..........................................................................................548 F-2 Anti-Lock Brake System Circuit Diagram..................................................................................550 F-3 Electronic Stability Program System Circuit Diagram.....................................................................552 F-4 Power Steering System Circuit Diagram...................................................................................554 G-1 Audio System Circuit Diagram............................................................................................556 G-2 Multi Information Display / Accessory Socket System Circuit Diagram.....................................................557 G-4 Navigation System Circuit Diagram.......................................................................................558 List of Connectors..............................................................................................................559 List of Connectors..........................................................................................................559 C Connector.................................................................................................................559 D Connector (DSL)...........................................................................................................560 E Connector.................................................................................................................561 F Connector.................................................................................................................563 G Connector.................................................................................................................563 J Connector.................................................................................................................565 K Connector.................................................................................................................566 L Connector.................................................................................................................567 O Connector.................................................................................................................569 R Connector.................................................................................................................569 Instrumentation / Driver Info. / Horn...............................................................................................570 Precautions.....................................................................................................................570 Precautions in Diagnosing Troubles for Combination Meter....................................................................570 General Description.............................................................................................................570 CAN Communication System Description........................................................................................570 Schematic and Routing Diagram...................................................................................................572 Combination Meter Circuit Diagram...........................................................................................572 Diagnostic Information and Procedures...........................................................................................573 Speedometer and VSS Symptom Diagnosis.......................................................................................573 Fuel Meter Symptom Diagnosis................................................................................................574 Low Fuel Warning Light Symptom Diagnosis....................................................................................574 Oil Pressure Warning Light Symptom Diagnosis................................................................................574 Information Display Symptom Diagnosis (If Equipped).........................................................................575 Repair Instructions.............................................................................................................576 Oil Pressure Switch Inspection..............................................................................................576 Seats...............................................................................................................................577 Diagnostic Information and Procedures...........................................................................................577 Front Seat Heater Symptom Diagnosis (If Equipped)...........................................................................577 Repair Instructions.............................................................................................................578 Front Seat Removal and Installation.........................................................................................578 Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)...............................................578 Front Seat Heater Wire Inspection (If Equipped).............................................................................578 Control systems.........................................................................................................................579 Precautions.........................................................................................................................581 Precautions.....................................................................................................................581 Precautions for Control Systems.............................................................................................581 Body Electrical Control System......................................................................................................582 General Description.............................................................................................................582 CAN Communication System Description........................................................................................582 Schematic and Routing Diagram...................................................................................................582 Body Electrical Control System Wiring Circuit Diagram.......................................................................582 Component Location..............................................................................................................585 BCM and Related System Component Location...................................................................................585 Diagnostic Information and Procedures...........................................................................................586 BCM Self-Diagnosis Function.................................................................................................586 DTC Table...................................................................................................................587 DTC U0073 (No. 0073): Control Module Communication Bus Off..................................................................588 DTC U0100 (No. 0100): Lost Communication with ECM...........................................................................590 Inspection of BCM and its Circuits..........................................................................................591 Immobilizer Control System..........................................................................................................599 Precautions.....................................................................................................................599 Precautions in Diagnosing Troubles..........................................................................................599 Precaution in Replacing Immobilizer Control System..........................................................................599 Precautions in Handling Immobilizer Control System..........................................................................600 General Description.............................................................................................................601 Immobilizer Control System Operation Description............................................................................601 Immobilizer Control System Components Description...........................................................................601 On-Board Diagnostic System Description......................................................................................602 Schematic and Routing Diagram...................................................................................................603 Immobilizer Control System Wiring Circuit Diagram...........................................................................603 Diagnostic Information and Procedures...........................................................................................604 Immobilizer Control System Check............................................................................................604 DTC Check...................................................................................................................604 DTC Clearance...............................................................................................................605 DTC Table...................................................................................................................605 Scan Tool Data..............................................................................................................606 SVS Lamp Does Not Come ON with Ignition Switch ON and Engine Stop...........................................................607 SVS Lamp Remains On after Ignition Switch ON................................................................................608 DTC B1000: Immobilizer Control Module Internal Failure......................................................................608 DTC B3040: W-Line Communication Failure.....................................................................................608 DTC B3042: W-Line Circuit Malfunction Shorted to Ground.....................................................................609 DTC B3043: W-Line Circuit Malfunction Shorted to Battery....................................................................609 DTC B3055: No Transponder...................................................................................................610 DTC B3056: No Fix Code Registered...........................................................................................611 DTC B3057: No Password Registered...........................................................................................612 DTC B3059: No Request from ECM..............................................................................................612 DTC B3060: Incorrect Transponder Detected...................................................................................613 DTC B3061: Transponder Communication Failure................................................................................614 DTC B3077: Read-Only Transponder Detected...................................................................................615 DTC P1610: Secret Key / Password Not Programed..............................................................................615 DTC P1611: Password Is Not Matched..........................................................................................616 DTC P1612 / P1613: No Signal from Immobilizer Control Module / Immobilizer System Malfunction...............................616 DTC P1614: Incorrect Signal from Immobilizer Control Module.................................................................617 DTC P1615: Steering Lock Unit Communication Error (for Vehicle with Keyless Start System)...................................617 DTC P1616: Unregistered Keyless Start Control Module (for Vehicle with Keyless Start System)................................618 DTC P1617: Keyless Start Control Module CAN Communication Error (for Vehicle with Keyless Start System).....................619 Inspection of Immobilizer Control Module and Its Circuit....................................................................620 Repair Instructions.............................................................................................................621 Immobilizer Control Module Removal and Installation.........................................................................621 How to Register Ignition Key................................................................................................622 Procedure after Immobilizer Control Module Replacement......................................................................622 Procedure after ECM Replacement.............................................................................................622 Registration Procedure of New Immobilizer Control System Components.........................................................623 Special Tools and Equipment.....................................................................................................623 Special Tool................................................................................................................623 Keyless Start System................................................................................................................624 Schematic and Routing Diagram...................................................................................................624 Keyless Start System Electric Wiring Circuit Diagram........................................................................624 Diagnostic Information and Procedures...........................................................................................625 Precautions in Diagnosing Troubles..........................................................................................625 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction..........................625 DTC No. 31: Lost Communication with BCM.....................................................................................626 DTC No. 33: Control Module Communication Bus Off............................................................................628 Repair Instructions.............................................................................................................630 Registration Procedure for Remote Controller ID Code........................................................................630 COPYRIGHT...............................................................................................................................632 BOOKCOVER............................................................................................................................... 0
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