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Suzuki SX4 RW420 Service Manual (Vol 1&2) – PDF DOWNLOAD
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Description
Suzuki SX4 RW420 Service Manual (Vol 1&2) – PDF DOWNLOAD
FILE DETAILS:
Suzuki SX4 RW420 Service Manual (Vol 1&2) – PDF DOWNLOAD
Language : English
Pages : 1539
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Suzuki SX4 RW420 Service Manual (Vol 1&2) – PDF DOWNLOAD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
- VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 5).
- VOLUME 2 contains Transmission/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and Control Systems sections (Sections 6 – 10).
Applicable Model:
SX4 (RW420) produced at KOSAI plant in Japan with following vehicle identification number (VIN) - The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced.
- The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki SX4 RW420 Service Manual (Vol 1&2) – PDF DOWNLOAD
TOP...................................................................................................................................................... 0 MANUAL LIST.............................................................................................................................................. 0 IMPORTANT................................................................................................................................................ 1 FOREWORD................................................................................................................................................. 3 TABLE OF CONTENTS........................................................................................................................................ 5 Precautions.............................................................................................................................................. 7 Precautions.......................................................................................................................................... 8 Precautions...................................................................................................................................... 8 Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System............................................................. 8 General Precautions.......................................................................................................................... 10 Warning for Wheel (with tire) Removal........................................................................................................ 13 Precautions in Servicing 4WD Model........................................................................................................... 14 Precautions for Catalytic Converter.......................................................................................................... 15 Precautions for Installing Mobile Communication Equipment.................................................................................... 15 Precaution for CAN Communication System...................................................................................................... 15 Precautions for Electrical Circuit Service................................................................................................... 15 Air Bag Warning.............................................................................................................................. 17 Fastener Caution............................................................................................................................. 17 Suspension Caution........................................................................................................................... 18 Wheels and Tires Caution..................................................................................................................... 18 ABS Caution.................................................................................................................................. 18 Brake Caution................................................................................................................................ 18 Repair Instructions.............................................................................................................................. 19 Electrical Circuit Inspection Procedure...................................................................................................... 19 Intermittent and Poor Connection Inspection.................................................................................................. 21 General Information...................................................................................................................................... 23 General Information.................................................................................................................................. 24 General Description.............................................................................................................................. 24 Abbreviations................................................................................................................................ 24 Symbols...................................................................................................................................... 25 Wire Color Symbols........................................................................................................................... 25 Fasteners Information........................................................................................................................ 26 Vehicle Lifting Points....................................................................................................................... 28 Vehicle Identification Number................................................................................................................ 29 Engine Identification Number................................................................................................................. 29 Transmission Identification Number........................................................................................................... 29 Component Location............................................................................................................................... 30 Warning, Caution and Information Labels Location............................................................................................. 30 Maintenance and Lubrication.......................................................................................................................... 32 Precautions...................................................................................................................................... 32 Precautions for Maintenance and Lubrication.................................................................................................. 32 Scheduled Maintenance............................................................................................................................ 32 Maintenance Schedule under Normal Driving Conditions......................................................................................... 32 Maintenance Recommended under Severe Driving Conditions...................................................................................... 33 Repair Instructions.............................................................................................................................. 34 Accessory Drive Belt Inspection.............................................................................................................. 34 Accessory Drive Belt Replacement............................................................................................................. 34 Valve Lash (Clearance) Inspection............................................................................................................ 34 Engine Oil and Filter Change................................................................................................................. 34 Engine Coolant Change........................................................................................................................ 34 Exhaust System Inspection.................................................................................................................... 34 Spark Plug Replacement....................................................................................................................... 34 Air Cleaner Filter Inspection................................................................................................................ 34 Air Cleaner Filter Replacement............................................................................................................... 34 Fuel Lines and Connections Inspection........................................................................................................ 34 Fuel Filter Replacement...................................................................................................................... 34 Fuel Tank Inspection......................................................................................................................... 35 PCV Valve Inspection......................................................................................................................... 35 Fuel Evaporative Emission Control System Inspection.......................................................................................... 35 Brake Discs and Pads Inspection.............................................................................................................. 35 Brake Drums and Shoes (Rear) Inspection...................................................................................................... 35 Brake Hoses and Pipes Inspection............................................................................................................. 35 Brake Fluid Replacement...................................................................................................................... 35 Brake Lever and Cable Inspection............................................................................................................. 35 Clutch Pedal Inspection...................................................................................................................... 35 Clutch Fluid Inspection...................................................................................................................... 35 Tires Inspection............................................................................................................................. 35 Wheel Discs Inspection....................................................................................................................... 35 Wheel Bearing Inspection..................................................................................................................... 35 Suspension System Inspection................................................................................................................. 35 Steering System Inspection................................................................................................................... 35 Drive Shaft (Axle) Boots Inspection.......................................................................................................... 35 Propeller Shaft (4WD) Inspection............................................................................................................. 35 Manual Transaxle Oil Inspection.............................................................................................................. 35 Manual Transaxle Oil Replacement............................................................................................................. 35 Automatic Transaxle Fluid Level Inspection................................................................................................... 35 Automatic Transaxle Fluid Replacement........................................................................................................ 35 Automatic Transaxle Fluid Cooler Hose Inspection............................................................................................. 35 Transfer Oil Inspection (4WD)................................................................................................................ 36 Transfer Oil Replacement (4WD)............................................................................................................... 36 Rear Deferential Oil Inspection (4WD)........................................................................................................ 36 Rear Deferential Oil Replacement (4WD)....................................................................................................... 36 All Latches, Hinges and Locks Inspection..................................................................................................... 36 HVAC Air Filter (If Equipped) Inspection..................................................................................................... 36 HVAC Air Filter (If Equipped) Replacement.................................................................................................... 36 Final Inspection for Maintenance Service..................................................................................................... 36 Special Tools and Equipment...................................................................................................................... 37 Recommended Fluids and Lubricants............................................................................................................ 37 Engine................................................................................................................................................... 39 Precautions.......................................................................................................................................... 44 Precautions...................................................................................................................................... 44 Precautions for Engine....................................................................................................................... 44 Engine General Information and Diagnosis............................................................................................................. 45 Precautions...................................................................................................................................... 45 Precautions on Engine Service................................................................................................................ 45 Precaution on On-Board Diagnostic (OBD) System............................................................................................... 45 Precautions in Diagnosing Trouble............................................................................................................ 45 Precautions for DTC Troubleshooting.......................................................................................................... 46 Precautions of ECM Circuit Inspection........................................................................................................ 46 Precautions of Electric Throttle Body System Calibration..................................................................................... 46 Precaution on CAN Troubleshooting............................................................................................................ 47 General Description.............................................................................................................................. 48 Statement on Cleanliness and Care............................................................................................................ 48 Engine Diagnosis General Description......................................................................................................... 49 On-Board Diagnostic System Description....................................................................................................... 49 DLC (Data Link Connector) Description........................................................................................................ 52 Engine and Emission Control System Description............................................................................................... 52 CAN Communication System Description......................................................................................................... 52 Air Intake System Description................................................................................................................ 54 Electric Throttle Body System Description.................................................................................................... 55 Description of Electric Throttle Body System Calibration..................................................................................... 56 A/F Sensor Description....................................................................................................................... 56 Electronic Control System Description........................................................................................................ 57 Engine and Emission Control Input / Output Table............................................................................................. 57 Schematic and Routing Diagram.................................................................................................................... 61 Engine and Emission Control System Diagram................................................................................................... 61 Engine and Emission Control System Flow Diagram.............................................................................................. 63 ECM Input / Output Circuit Diagram........................................................................................................... 64 Component Location............................................................................................................................... 68 Electronic Control System Components Location................................................................................................ 68 Diagnostic Information and Procedures............................................................................................................ 69 Engine and Emission Control System Check..................................................................................................... 69 Malfunction Indicator Lamp (MIL) Check....................................................................................................... 72 DTC Check.................................................................................................................................... 73 DTC Clearance................................................................................................................................ 73 Troubleshooting for Communication Error with Scan Tool Using CAN............................................................................. 73 DTC Table.................................................................................................................................... 78 Fail-Safe Table.............................................................................................................................. 84 Scan Tool Data............................................................................................................................... 86 Visual Inspection............................................................................................................................ 91 Engine Basic Inspection...................................................................................................................... 91 Engine Symptom Diagnosis..................................................................................................................... 93 MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)..................................................... 99 MIL Remains ON after Engine Starts........................................................................................................... 101 DTC P0030: HO2S Heater Control Circuit (Sensor-1, Bank-1).................................................................................... 102 DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1, Bank-1)................................................................. 103 DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2, Bank-1)................................................................. 105 DTC P0101: Mass or Volume Air Flow Circuit Range / Performance............................................................................... 106 DTC P0102 / P0103: Mass or Volume Air Flow Circuit Low / High Input.......................................................................... 108 DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance....................................................................... 110 DTC P0112 / P0113: Intake Air Temperature Sensor Circuit Low / High Input.................................................................... 110 DTC P0116: Engine Coolant Temperature Circuit Range / Performance............................................................................ 112 DTC P0117 / P0118: Engine Coolant Temperature Circuit Low / High............................................................................. 114 DTC P0122 / P0123: Throttle / Pedal Position Sensor / Switch “A” Circuit Low / High.......................................................... 115 DTC P0131 / P0132: O2 Sensor Circuit Low Voltage / High Voltage (Sensor-1, Bank-1)........................................................... 118 DTC P0133: O2 Sensor Circuit Slow Response / Performance (Sensor-1, Bank-1).................................................................. 119 DTC P0134: O2 Sensor Circuit No Activity Detected (Sensor-1, Bank-1)......................................................................... 121 DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2, Bank-1).................................................... 122 DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2, Bank-1).................................................................. 124 DTC P0171 / P0172: System Too Lean / Too Rich (Sensor-1, Bank-1)............................................................................. 125 DTC P0222 / P0223: Throttle Position Sensor (Sub) Circuit Low / High......................................................................... 127 DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...... 129 DTC P0327 / P0328: Knock Sensor Circuit Low / High........................................................................................... 131 DTC P0335: Crankshaft Position Sensor “A” Circuit............................................................................................ 132 DTC P0340: Camshaft Position Sensor “A” Circuit.............................................................................................. 134 DTC P0420: Catalyst System Efficiency Below Threshold (Bank-1)............................................................................... 136 DTC P0443: EVAP Emission System Purge Control Valve Circuit.................................................................................. 138 DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High...................................................................................... 140 DTC P0480: Fan 1 Control Circuit............................................................................................................. 142 DTC P0481: Fan 2 Control Circuit............................................................................................................. 145 DTC P0500: Vehicle Speed Sensor “A”.......................................................................................................... 147 DTC P0504: Brake Switch “A”/“B” Correlation.................................................................................................. 148 DTC P0532 / P0533: A/C Refrigerant Pressure Sensor Circuit Low / High........................................................................ 150 DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance.... 151 DTC P0616 / P0617: Starter Relay Circuit Low / High.......................................................................................... 152 DTC P0660 / P0662: Intake Manifold Tuning Valve Control Circuit Open / High.................................................................. 154 DTC P1510: ECM Back-Up Power Supply Malfunction.............................................................................................. 155 DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance....................................................................... 156 DTC P2102: Throttle Actuator Control Motor Circuit Low....................................................................................... 157 DTC P2103: Throttle Actuator Control Motor Circuit High...................................................................................... 159 DTC P2111: Throttle Actuator Control System - Stuck Open..................................................................................... 159 DTC P2119: Throttle Actuator Control Throttle Body Range / Performance....................................................................... 160 DTC P2122 / P2123: Throttle / Pedal Position Sensor / Switch “D” Circuit Low / High.......................................................... 161 DTC P2127 / P2128: Throttle / Pedal Position Sensor / Switch “E” Circuit Low / High Input.................................................... 163 DTC P2135: Throttle / Pedal Position Sensor / Switch “A” / “B” Voltage Correction............................................................ 165 DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correction............................................................................. 166 DTC P2195 / P2196: O2 Sensor Signal Stuck Lean / Stuck Rich (Sensor-1, Bank-1)............................................................... 167 DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Performance / Low / High.............................................................. 168 DTC U0073: Control Module Communication Bus Off.............................................................................................. 169 DTC U0101: Lost Communication with TCM....................................................................................................... 169 DTC U0121: Lost Communication with ABS / ESP‚ Control Module................................................................................. 169 DTC U0140: Lost Communication with Body Control Module....................................................................................... 169 Troubleshooting for CAN-DTC.................................................................................................................. 169 Inspection of ECM and Its Circuits........................................................................................................... 174 ECM Power and Ground Circuit Check........................................................................................................... 192 Fuel Injector Circuit Check.................................................................................................................. 195 Fuel Pump and Its Circuit Check.............................................................................................................. 197 Fuel Pressure Check.......................................................................................................................... 200 A/C Condenser Cooling Fan Control System Inspection.......................................................................................... 202 A/C System Circuits Check.................................................................................................................... 204 Electric Load Signal Circuit Check........................................................................................................... 207 Radiator Cooling Fan Low Speed Control System Check.......................................................................................... 209 Radiator Cooling Fan High Speed Control System Check......................................................................................... 211 Repair Instructions.............................................................................................................................. 212 Idle Speed and IAC Throttle Valve Opening Inspection......................................................................................... 212 Special Tools and Equipment...................................................................................................................... 213 Special Tool................................................................................................................................. 213 Aux. Emission Control Devices........................................................................................................................ 214 Diagnostic Information and Procedures............................................................................................................ 214 EVAP Canister Purge System Inspection........................................................................................................ 214 Repair Instructions.............................................................................................................................. 215 EVAP System Components....................................................................................................................... 215 EVAP Canister Purge Inspection............................................................................................................... 215 EVAP Canister Purge Valve and Its Circuit Inspection......................................................................................... 216 Vacuum Passage Inspection.................................................................................................................... 217 Vacuum Hose and Purge Valve Chamber Inspection............................................................................................... 217 EVAP Canister Purge Valve Inspection......................................................................................................... 217 EVAP Canister Removal and Installation....................................................................................................... 218 EVAP Canister Inspection..................................................................................................................... 218 PCV Hose Inspection.......................................................................................................................... 218 PCV Valve Removal and Installation........................................................................................................... 218 PCV Valve Inspection......................................................................................................................... 219 Specifications................................................................................................................................... 219 Tightening Torque Specifications............................................................................................................. 219 Special Tools and Equipment...................................................................................................................... 219 Recommended Service Material................................................................................................................. 219 Special Tool................................................................................................................................. 219 Engine Electrical Devices............................................................................................................................ 220 Repair Instructions.............................................................................................................................. 220 Engine Control Module (ECM) Removal and Installation......................................................................................... 220 Electric Throttle Body Assembly On-Vehicle Inspection........................................................................................ 221 Electric Throttle Body System Calibration.................................................................................................... 223 Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection....................................................................... 223 Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation.................................................................... 224 Accelerator Pedal Position (APP) Sensor Assembly Inspection.................................................................................. 224 Engine Coolant Temperature (ECT) Sensor Removal and Installation............................................................................. 225 Engine Coolant Temperature (ECT) Sensor Inspection........................................................................................... 225 Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection............................................................................................ 226 Heated Oxygen Sensor (HO2S) Heater On- Vehicle Inspection.................................................................................... 226 Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S) Removal and Installation............................................................ 226 Camshaft Position (CMP) Sensor Removal and Installation...................................................................................... 227 Camshaft Position (CMP) Sensor Inspection.................................................................................................... 227 Crankshaft Position (CKP) Sensor Removal and Installation.................................................................................... 227 Crankshaft Position (CKP) Sensor Inspection.................................................................................................. 228 Knock Sensor Removal and Installation........................................................................................................ 228 Engine and Emission Control System Relay Inspection.......................................................................................... 229 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection............................................................ 229 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation......................................................... 230 Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection....................................................................... 230 IMT Valve Actuator Inspection................................................................................................................ 231 Specifications................................................................................................................................... 231 Tightening Torque Specifications............................................................................................................. 231 Engine Mechanical.................................................................................................................................... 232 General Description.............................................................................................................................. 232 Engine Construction.......................................................................................................................... 232 IMT (Intake Manifold Tuning) System Description.............................................................................................. 233 Diagnostic Information and Procedures............................................................................................................ 234 Compression Check............................................................................................................................ 234 Engine Vacuum Check.......................................................................................................................... 235 Valve Lash (Clearance) Inspection............................................................................................................ 235 Repair Instructions.............................................................................................................................. 238 Air Cleaner Components....................................................................................................................... 238 Air Cleaner Assembly Removal and Installation................................................................................................ 239 Air Cleaner Filter Removal and Installation.................................................................................................. 239 Air Cleaner Filter Inspection and Cleaning................................................................................................... 239 Electric Throttle Body and Intake Manifold Components........................................................................................ 240 Electric Throttle Body On-Vehicle Inspection................................................................................................. 241 Electric Throttle Body Assembly Removal and Installation..................................................................................... 241 Electric Throttle Body Cleaning.............................................................................................................. 241 Intake Manifold Removal and Installation..................................................................................................... 242 IMT Valve Actuator Removal and Installation.................................................................................................. 243 Cylinder Head Cover Components............................................................................................................... 243 Cylinder Head Cover Removal and Installation................................................................................................. 243 Engine Mountings Components.................................................................................................................. 245 Engine Assembly Removal and Installation..................................................................................................... 246 Timing Chain Cover Components................................................................................................................ 250 Timing Chain Cover Removal and Installation.................................................................................................. 250 Timing Chain Cover Cleaning and Inspection................................................................................................... 253 2nd Timing Chain and Chain Tensioner Components.............................................................................................. 253 2nd Timing Chain and Chain Tensioner Removal and Installation................................................................................ 254 2nd Timing Chain and Chain Tensioner Inspection.............................................................................................. 257 1st Timing Chain and Chain Tensioner Components.............................................................................................. 258 1st Timing Chain and Chain Tensioner Removal and Installation................................................................................ 258 1st Timing Chain and Chain Tensioner Inspection.............................................................................................. 260 Camshafts, Tappet and Shim Components........................................................................................................ 261 Camshafts, Tappet and Shim Removal and Installation.......................................................................................... 262 Camshaft, Tappet and Shim Inspection......................................................................................................... 263 Valves and Cylinder Head Components.......................................................................................................... 266 Valves and Cylinder Head Removal and Installation............................................................................................ 266 Valves and Cylinder Head Disassembly and Reassembly.......................................................................................... 268 Valves and Valve Guides Inspection........................................................................................................... 271 Cylinder Head Inspection..................................................................................................................... 273 Valve Spring Inspection...................................................................................................................... 274 Pistons, Piston Rings, Connecting Rods and Cylinders Components.............................................................................. 275 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation................................................................ 276 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly.............................................................. 277 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning................................................................. 279 Main Bearings, Crankshaft and Cylinder Block Components...................................................................................... 286 Main Bearings, Crankshaft and Cylinder Block Removal and Installation........................................................................ 287 Main Bearings, Crankshaft and Cylinder Block Inspection...................................................................................... 290 Specifications................................................................................................................................... 296 Tightening Torque Specifications............................................................................................................. 296 Special Tools and Equipment...................................................................................................................... 298 Recommended Service Material................................................................................................................. 298 Special Tool................................................................................................................................. 298 Engine Lubrication System............................................................................................................................ 300 General Description.............................................................................................................................. 300 Engine Lubrication Description............................................................................................................... 300 Diagnostic Information and Procedures............................................................................................................ 301 Oil Pressure Check........................................................................................................................... 301 Repair Instructions.............................................................................................................................. 302 Engine Oil and Filter Change................................................................................................................. 302 Oil Pan and Oil Pump Strainer Components..................................................................................................... 304 Oil Pan and Oil Pump Strainer Removal and Installation....................................................................................... 305 Oil Pan and Oil Pump Strainer Cleaning....................................................................................................... 306 Oil Pump Components.......................................................................................................................... 307 Oil Pump Removal and Installation............................................................................................................ 308 Oil Pump Disassembly and Reassembly.......................................................................................................... 309 Oil Pump Inspection.......................................................................................................................... 309 Specifications................................................................................................................................... 310 Tightening Torque Specifications............................................................................................................. 310 Special Tools and Equipment...................................................................................................................... 311 Recommended Service Material................................................................................................................. 311 Special Tool................................................................................................................................. 311 Engine Cooling System................................................................................................................................ 312 General Description.............................................................................................................................. 312 Cooling System Description................................................................................................................... 312 Coolant Description.......................................................................................................................... 312 Schematic and Routing Diagram.................................................................................................................... 313 Coolant Circulation.......................................................................................................................... 313 Diagnostic Information and Procedures............................................................................................................ 314 Engine Cooling Symptom Diagnosis............................................................................................................. 314 Repair Instructions.............................................................................................................................. 315 Cooling System Components.................................................................................................................... 315 Coolant Level Check.......................................................................................................................... 316 Engine Cooling System Inspection and Cleaning................................................................................................ 316 Cooling System Draining...................................................................................................................... 316 Cooling System Flush and Refill.............................................................................................................. 317 Cooling Water Pipes or Hoses Removal and Installation........................................................................................ 317 Thermostat Removal and Installation.......................................................................................................... 318 Thermostat Inspection........................................................................................................................ 318 Radiator Cooling Fan Assembly Inspection..................................................................................................... 319 Radiator Cooling Fan Relay Inspection........................................................................................................ 319 Radiator Cooling Fan Assembly Removal and Installation....................................................................................... 319 Radiator Cooling Fan Disassembly and Reassembly.............................................................................................. 320 Radiator On-Vehicle Inspection and Cleaning.................................................................................................. 320 Radiator Removal and Installation............................................................................................................ 320 Water Pump Removal and Installation.......................................................................................................... 321 Water Pump Inspection........................................................................................................................ 321 Specifications................................................................................................................................... 321 Tightening Torque Specifications............................................................................................................. 321 Fuel System.......................................................................................................................................... 322 Precautions...................................................................................................................................... 322 Precautions on Fuel System Service........................................................................................................... 322 General Description.............................................................................................................................. 322 Fuel System Description...................................................................................................................... 322 Fuel Delivery System Description............................................................................................................. 322 Fuel Pump Description........................................................................................................................ 323 Schematic and Routing Diagram.................................................................................................................... 323 Fuel Delivery System Diagram................................................................................................................. 323 Diagnostic Information and Procedures............................................................................................................ 323 Fuel Pressure Inspection..................................................................................................................... 323 Fuel Cut Operation Inspection................................................................................................................ 324 Repair Instructions.............................................................................................................................. 325 Fuel System Components....................................................................................................................... 325 Fuel Hose Disconnecting and Reconnecting..................................................................................................... 326 Fuel Pressure Relief Procedure............................................................................................................... 328 Fuel Leakage Check Procedure................................................................................................................. 328 Fuel Tank, Cap Gasket and Fuel Line Inspection............................................................................................... 328 Fuel Pipe Removal and Installation........................................................................................................... 329 Fuel Injector On-Vehicle Inspection.......................................................................................................... 329 Fuel Injector Removal and Installation....................................................................................................... 330 Fuel Injector Inspection..................................................................................................................... 331 Fuel Filler Cap Inspection................................................................................................................... 332 Fuel Tank Inlet Valve Removal and Installation............................................................................................... 333 Fuel Tank Inlet Valve Inspection............................................................................................................. 333 Fuel Tank Removal and Installation........................................................................................................... 333 Fuel Tank Inspection......................................................................................................................... 336 Fuel Tank Purging Procedure.................................................................................................................. 336 Fuel Pump On-Vehicle Inspection.............................................................................................................. 336 Fuel Filter Replacement...................................................................................................................... 337 Fuel Pump Assembly Removal and Installation.................................................................................................. 337 Main Fuel Level Sensor Removal and Installation.............................................................................................. 338 Fuel Pump Inspection......................................................................................................................... 338 Specifications................................................................................................................................... 339 Tightening Torque Specifications............................................................................................................. 339 Special Tools and Equipment...................................................................................................................... 339 Special Tool................................................................................................................................. 339 Ignition System...................................................................................................................................... 340 General Description.............................................................................................................................. 340 Ignition System Construction................................................................................................................. 340 Schematic and Routing Diagram.................................................................................................................... 341 Ignition System Wiring Circuit Diagram....................................................................................................... 341 Component Location............................................................................................................................... 342 Ignition System Components Location.......................................................................................................... 342 Diagnostic Information and Procedures............................................................................................................ 342 Ignition System Check........................................................................................................................ 342 Ignition System Symptom Diagnosis............................................................................................................ 344 Reference Waveform of Ignition System........................................................................................................ 344 Ignition Spark Test.......................................................................................................................... 344 Repair Instructions.............................................................................................................................. 345 Spark Plug Removal and Installation.......................................................................................................... 345 Spark Plug Inspection........................................................................................................................ 345 Ignition Coil Assembly (Including ignitor) Removal and Installation.......................................................................... 345 Ignition Coil Assembly (Including ignitor) Inspection........................................................................................ 345 Ignition Timing Inspection................................................................................................................... 346 Specifications................................................................................................................................... 347 Tightening Torque Specifications............................................................................................................. 347 Special Tools and Equipment...................................................................................................................... 347 Special Tool................................................................................................................................. 347 Starting System...................................................................................................................................... 348 Schematic and Routing Diagram.................................................................................................................... 348 Cranking System Circuit Diagram.............................................................................................................. 348 Diagnostic Information and Procedures............................................................................................................ 348 Cranking System Symptom Diagnosis............................................................................................................ 348 Cranking System Test......................................................................................................................... 350 Repair Instructions.............................................................................................................................. 351 Starting Motor Unit Components............................................................................................................... 351 Starting Motor Dismounting and Remounting.................................................................................................... 351 Starting Motor Components.................................................................................................................... 352 Starting Motor Inspection.................................................................................................................... 353 Specifications................................................................................................................................... 356 Cranking System Specifications............................................................................................................... 356 Tightening Torque Specifications............................................................................................................. 356 Special Tools and Equipment...................................................................................................................... 356 Recommended Service Material................................................................................................................. 356 Charging System...................................................................................................................................... 357 General Description.............................................................................................................................. 357 Battery Description.......................................................................................................................... 357 Generator Description........................................................................................................................ 358 Diagnostic Information and Procedures............................................................................................................ 360 Battery Inspection........................................................................................................................... 360 Generator Symptom Diagnosis.................................................................................................................. 360 Generator Test (Undercharged Battery Check).................................................................................................. 361 Generator Test (Overcharged Battery Check)................................................................................................... 362 Repair Instructions.............................................................................................................................. 362 Jump Starting in Case of Emergency........................................................................................................... 362 Battery Dismounting and Remounting........................................................................................................... 363 Water Pump and Generator Drive Belt On-Vehicle Inspection.................................................................................... 364 Water Pump and Generator Drive Belt Removal and Installation................................................................................. 364 Generator Unit Components.................................................................................................................... 365 Generator Dismounting and Remounting......................................................................................................... 366 Generator Components......................................................................................................................... 367 Generator Inspection......................................................................................................................... 368 Specifications................................................................................................................................... 371 Charging System Specifications............................................................................................................... 371 Tightening Torque Specifications............................................................................................................. 371 Exhaust System....................................................................................................................................... 372 General Description.............................................................................................................................. 372 Exhaust System Description................................................................................................................... 372 Diagnostic Information and Procedures............................................................................................................ 372 Exhaust System Check......................................................................................................................... 372 Repair Instructions.............................................................................................................................. 373 Exhaust System Components.................................................................................................................... 373 Exhaust Manifold Removal and Installation.................................................................................................... 374 Exhaust Pipe and Muffler Removal and Installation............................................................................................ 375 Specifications................................................................................................................................... 376 Tightening Torque Specifications............................................................................................................. 376 Suspension............................................................................................................................................... 377 Precautions.......................................................................................................................................... 379 Precautions...................................................................................................................................... 379 Precautions on Suspension.................................................................................................................... 379 Suspension General Diagnosis......................................................................................................................... 380 Diagnostic Information and Procedures............................................................................................................ 380 Suspension, Wheels and Tires Symptom Diagnosis............................................................................................... 380 Repair Instructions.............................................................................................................................. 382 Suspension System Inspection................................................................................................................. 382 Wheel Bearing Inspection..................................................................................................................... 382 Front Suspension..................................................................................................................................... 383 General Description.............................................................................................................................. 383 Front Suspension Construction................................................................................................................ 383 Front Wheel Alignment Construction........................................................................................................... 384 Repair Instructions.............................................................................................................................. 384 Front Wheel Alignment Inspection and Adjustment.............................................................................................. 384 Camber and Caster Check...................................................................................................................... 385 Steering Angle Check......................................................................................................................... 386 Front Strut Assembly Components.............................................................................................................. 386 Front Strut Assembly Removal and Installation................................................................................................ 387 Front Strut Assembly Disassembly and Reassembly.............................................................................................. 388 Front Strut Assembly Check................................................................................................................... 389 Front Wheel Hub and Steering Knuckle Components.............................................................................................. 390 Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation................................................................. 390 Front Wheel Bearing and Wheel Hub Inspection................................................................................................. 394 Suspension Control Arm Removal and Installation.............................................................................................. 395 Suspension Control Arm Bush Disassembly and Assembly......................................................................................... 396 Suspension Control Arm / Steering Knuckle Check.............................................................................................. 396 Suspension Control Arm Bush Check............................................................................................................ 396 Suspension Control Arm Joint Check........................................................................................................... 397 Front Suspension Frame, Stabilizer Bar and/or Bush Components................................................................................ 397 Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation (2WD Model)...................................................... 398 Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation (4WD Model)...................................................... 400 Front Suspension Frame Check................................................................................................................. 401 Front Stabilizer Bar, Bush and/or Joint Check................................................................................................ 401 Front Suspension Fasteners Check............................................................................................................. 401 Specifications................................................................................................................................... 402 Tightening Torque Specifications............................................................................................................. 402 Special Tools and Equipment...................................................................................................................... 403 Recommended Service Material................................................................................................................. 403 Special Tool................................................................................................................................. 403 Rear Suspension...................................................................................................................................... 404 General Description.............................................................................................................................. 404 Rear Suspension Constructions................................................................................................................ 404 Repair Instructions.............................................................................................................................. 405 Rear Wheel Alignment Inspection.............................................................................................................. 405 Rear Shock Absorber Removal and Installation................................................................................................. 405 Rear Shock Absorber Inspection............................................................................................................... 407 Rear Shock Absorber Bush Inspection.......................................................................................................... 407 Rear Coil Spring Removal and Installation.................................................................................................... 407 Spring Upper Seat / Spring Lower Seat Inspection............................................................................................. 409 Rear Axle Removal and Installation (Rear Drum Brake Model)................................................................................... 409 Rear Axle Removal and Installation (Rear Disc Brake Model)................................................................................... 410 Rear Axle and Coil Spring Inspection......................................................................................................... 412 Rear Axle Bush Inspection.................................................................................................................... 412 Rear Wheel Hub Assembly Inspection........................................................................................................... 412 Rear Wheel Hub Assembly Removal and Installation (Rear Drum Brake Model)..................................................................... 413 Rear Wheel Hub Assembly Removal and Installation (Rear Disc Brake Model)..................................................................... 415 Rear Suspension Fasteners Inspection......................................................................................................... 416 Specifications................................................................................................................................... 417 Tightening Torque Specifications............................................................................................................. 417 Wheels and Tires..................................................................................................................................... 418 Precautions...................................................................................................................................... 418 Precautions in Wheels and Tires Servicing.................................................................................................... 418 General Description.............................................................................................................................. 418 Tires Description............................................................................................................................ 418 Wheels Description........................................................................................................................... 419 Irregular and/or Premature Wear Description.................................................................................................. 420 Wear Indicators Description.................................................................................................................. 420 Radial Tire Waddle Description............................................................................................................... 421 Radial Tire Lead / Pull Description.......................................................................................................... 422 Balancing Wheels Description................................................................................................................. 422 Repair Instructions.............................................................................................................................. 422 Wheel Discs Inspection....................................................................................................................... 422 Tires Inspection............................................................................................................................. 422 Wheel Balance Inspection and Adjustment...................................................................................................... 422 Tire Rotation................................................................................................................................ 423 Wheel (with Tire) Removal and Installation................................................................................................... 423 Tire Mounting and Dismounting................................................................................................................ 424 Tire Repair.................................................................................................................................. 424 Specifications................................................................................................................................... 424 Wheels and Tires Specifications.............................................................................................................. 424 Tightening Torque Specifications............................................................................................................. 424 Driveline / Axle......................................................................................................................................... 425 Precautions.......................................................................................................................................... 427 Precautions...................................................................................................................................... 427 Precautions on Driveline / Axle.............................................................................................................. 427 Drive Shaft / Axle................................................................................................................................... 428 Front............................................................................................................................................ 428 General Description.......................................................................................................................... 428 Front Drive Shaft Construction........................................................................................................... 428 Component Location........................................................................................................................... 428 Front Drive Shaft Assembly Components Location........................................................................................... 428 Diagnostic Information and Procedures........................................................................................................ 429 Front Drive Shaft Symptom Diagnosis...................................................................................................... 429 Repair Instructions.......................................................................................................................... 429 Front Drive Shaft Components............................................................................................................. 429 Front Drive Shaft Assembly On-Vehicle Inspection......................................................................................... 429 Front Drive Shaft Assembly Removal and Installation...................................................................................... 429 Front Drive Shaft Disassembly and Reassembly............................................................................................. 431 Center Shaft and Center Bearing Support Disassembly and Reassembly (2WD Model)........................................................... 434 Specifications............................................................................................................................... 435 Tightening Torque Specifications......................................................................................................... 435 Special Tools and Equipment.................................................................................................................. 436 Recommended Service Material............................................................................................................. 436 Special Tool............................................................................................................................. 436 Rear............................................................................................................................................. 437 General Description.......................................................................................................................... 437 Rear Drive Shaft Construction............................................................................................................ 437 Repair Instructions.......................................................................................................................... 437 Rear Drive Shaft Components.............................................................................................................. 437 Rear Drive Shaft Assembly Removal and Installation....................................................................................... 438 Rear Drive Shaft Disassembly and Reassembly.............................................................................................. 438 Specifications............................................................................................................................... 440 Tightening Torque Specifications......................................................................................................... 440 Special Tools and Equipment.................................................................................................................. 440 Recommended Service Material............................................................................................................. 440 Special Tool............................................................................................................................. 440 Differential......................................................................................................................................... 441 Precautions...................................................................................................................................... 441 Precaution for Rear Differential Oil Leakage................................................................................................. 441 Precautions in Diagnosing Trouble............................................................................................................ 441 General Description.............................................................................................................................. 442 Rear Differential Description................................................................................................................ 442 Coupling Description......................................................................................................................... 442 4WD Control System Description............................................................................................................... 443 Function of 4WD Control System Component..................................................................................................... 443 Input / Output Signal Table of 4WD Control Module............................................................................................ 443 On-Board Diagnostic System Description....................................................................................................... 444 CAN Communication System Description......................................................................................................... 445 Schematic and Routing Diagram.................................................................................................................... 446 4WD Control System Wiring Circuit Diagram.................................................................................................... 446 Component Location............................................................................................................................... 447 4WD Control System Components Location....................................................................................................... 447 Diagnostic Information and Procedures............................................................................................................ 448 4WD Control System Check..................................................................................................................... 448 4WD Position Indicator Operation Check....................................................................................................... 450 4WD Control System Operation Inspection...................................................................................................... 450 Visual Inspection............................................................................................................................ 450 DTC Check.................................................................................................................................... 451 DTC Clearance................................................................................................................................ 451 DTC Table.................................................................................................................................... 452 Fail-Safe Table.............................................................................................................................. 452 Scan Tool Data............................................................................................................................... 453 Rear Differential Symptom Diagnosis.......................................................................................................... 454 4WD Control Symptom Diagnosis................................................................................................................ 454 4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops............................................................... 455 4WD Position Indicator Remains ON Steady at Ignition Switch ON............................................................................... 456 DTC C1240: 4WD Control Module Power Supply Circuit Malfunction............................................................................... 457 DTC C1243: Internal Circuit Malfunction of 4WD Control Module................................................................................ 458 DTC C1250: Coupling Air Temperature Sensor Circuit Open...................................................................................... 458 DTC C1251: Coupling Air Temperature Sensor Circuit Short..................................................................................... 460 DTC C1252: Coupling Assembly Circuit Open.................................................................................................... 461 DTC C1253: Coupling Assembly Circuit Short................................................................................................... 463 DTC C1254: 2WD/4WD Switch Malfunction........................................................................................................ 464 DTC U0073: Control Module Communication Bus Off.............................................................................................. 466 DTC U0100: Lost Communication with ECM....................................................................................................... 466 DTC U0121: Lost Communication with ABS / ESP‚ Control Module................................................................................. 466 DTC U0155: Lost Communication with Instrument Panel Cluster (IPC) Control Module............................................................. 466 Inspection of 4WD Control Module and Its Circuits............................................................................................ 466 Repair Instructions.............................................................................................................................. 469 Rear Differential Oil Level Check............................................................................................................ 469 Rear Differential Oil Change................................................................................................................. 469 2WD/4WD Switch Removal and Installation...................................................................................................... 470 2WD/4WD Switch Inspection.................................................................................................................... 470 4WD Control Module Removal and Installation.................................................................................................. 470 Coupling Air Temperature Sensor Removal and Installation..................................................................................... 470 Coupling Air Temperature Sensor Inspection................................................................................................... 471 Coupling Assembly Inspection................................................................................................................. 471 Rear Differential Mountings Components....................................................................................................... 472 Front Mounting Arm and/or Rear Mounting Bracket Assembly Removal and Installation............................................................ 473 Rear Mounting Bracket Assembly Disassembly and Reassembly.................................................................................... 473 Rear Differential Dismounting and Remounting................................................................................................. 473 Rear Differential Components................................................................................................................. 474 Rear Differential Disassembly and Reassembly................................................................................................. 475 Rear Differential Inspection................................................................................................................. 486 Specifications................................................................................................................................... 486 Tightening Torque Specifications............................................................................................................. 486 Special Tools and Equipment...................................................................................................................... 487 Recommended Service Material................................................................................................................. 487 Special Tool................................................................................................................................. 487 Transfer............................................................................................................................................. 490 General Description.............................................................................................................................. 490 Transfer Description......................................................................................................................... 490 Diagnostic Information and Procedures............................................................................................................ 490 Transfer Symptom Diagnosis................................................................................................................... 490 Repair Instructions.............................................................................................................................. 491 Transfer Oil Level Check..................................................................................................................... 491 Transfer Oil Change.......................................................................................................................... 491 Transfer Dismounting and Remounting.......................................................................................................... 492 Transfer Assembly Components................................................................................................................. 494 Transfer Assembly Disassembly and Reassembly................................................................................................. 495 Reduction Drive Gear Assembly Disassembly and Reassembly..................................................................................... 497 Reduction Driven Gear Assembly Disassembly and Reassembly.................................................................................... 498 Transfer Right Case and Left Case Disassembly and Reassembly................................................................................. 499 Transfer Output Retainer Assembly Disassembly and Reassembly................................................................................. 500 Transfer Assembly Inspection................................................................................................................. 504 Bevel Gear Tooth Contact Inspection.......................................................................................................... 504 Specifications................................................................................................................................... 506 Tightening Torque Specifications............................................................................................................. 506 Special Tools and Equipment...................................................................................................................... 507 Recommended Service Material................................................................................................................. 507 Special Tool................................................................................................................................. 507 Propeller Shaft...................................................................................................................................... 509 General Description.............................................................................................................................. 509 Propeller Shaft Construction................................................................................................................. 509 Diagnostic Information and Procedures............................................................................................................ 509 Propeller Shaft Symptom Diagnosis............................................................................................................ 509 Repair Instructions.............................................................................................................................. 509 Propeller Shaft Joint Check.................................................................................................................. 509 Propeller Shaft Assembly Removal and Installation............................................................................................ 510 Propeller Shaft Inspection................................................................................................................... 510 Specifications................................................................................................................................... 510 Tightening Torque Specifications............................................................................................................. 510 Brakes................................................................................................................................................... 511 Precautions.......................................................................................................................................... 513 Precautions...................................................................................................................................... 513 Precautions for Brakes....................................................................................................................... 513 Brake Control System and Diagnosis................................................................................................................... 514 Precautions...................................................................................................................................... 514 Precautions on Brake......................................................................................................................... 514 General Description.............................................................................................................................. 514 Brakes Construction.......................................................................................................................... 514 Brake Pedal Foot Protection System Construction (If Equipped)................................................................................ 515 Diagnostic Information and Procedures............................................................................................................ 515 Brakes Diagnosis Note........................................................................................................................ 515 Brakes Symptom Diagnosis..................................................................................................................... 516 Repair Instructions.............................................................................................................................. 518 Brake Pedal Components....................................................................................................................... 518 Brake Pedal Free Height Inspection........................................................................................................... 518 Brake Pedal Play Inspection.................................................................................................................. 518 Excessive Pedal Travel Inspection............................................................................................................ 518 Master Cylinder and Brake Fluid Level Inspection............................................................................................. 519 Brake Fluid Replacement...................................................................................................................... 519 Brake Light Switch Adjustment................................................................................................................ 519 Air Bleeding of Brake System................................................................................................................. 519 Front Brake Hose and Pipe Components......................................................................................................... 521 Front Brake Hose and Pipe Removal and Installation........................................................................................... 522 Rear Brake Hose and Pipe Components.......................................................................................................... 523 Rear Brake Hose and Pipe Removal and Installation............................................................................................ 524 Brake Hose and Pipe Inspection............................................................................................................... 524 Master Cylinder and Brake Booster Components................................................................................................. 525 Master Cylinder Reservoir Removal and Installation........................................................................................... 525 Master Cylinder Removal and Installation..................................................................................................... 526 Master Cylinder Inspection................................................................................................................... 527 Booster Operation Inspection................................................................................................................. 528 Brake Booster Removal and Installation....................................................................................................... 529 Brake Booster Inspection..................................................................................................................... 529 Booster Push Clevis Rod Adjustment........................................................................................................... 530 Specifications................................................................................................................................... 530 Tightening Torque Specifications............................................................................................................. 530 Special Tools and Equipment...................................................................................................................... 530 Recommended Service Material................................................................................................................. 530 Special Tool................................................................................................................................. 530 Front Brakes......................................................................................................................................... 531 Repair Instructions.............................................................................................................................. 531 Front Disc Brake Components.................................................................................................................. 531 Front Disc Brake Pad On-Vehicle Inspection................................................................................................... 532 Front Disc Brake Pad Removal and Installation................................................................................................ 532 Front Disc Brake Pad Inspection.............................................................................................................. 533 Front Disc Brake Caliper Removal and Installation............................................................................................ 533 Front Disc Brake Caliper Disassembly and Assembly............................................................................................ 534 Front Disc Brake Caliper Check............................................................................................................... 536 Front Brake Disc Removal and Installation.................................................................................................... 537 Front Brake Disc Inspection.................................................................................................................. 537 Specifications................................................................................................................................... 538 Tightening Torque Specifications............................................................................................................. 538 Special Tools and Equipment...................................................................................................................... 538 Recommended Service Material................................................................................................................. 538 Special Tool................................................................................................................................. 538 Rear Brakes.......................................................................................................................................... 539 Drum............................................................................................................................................. 539 Repair Instructions.......................................................................................................................... 539 Rear Drum Brake Components............................................................................................................... 539 Rear Brake Drum Removal and Installation................................................................................................. 540 Rear Brake Drum and Shoe Inspection...................................................................................................... 540 Rear Brake Shoe On-Vehicle Inspection.................................................................................................... 541 Rear Brake Shoe Removal and Installation................................................................................................. 541 Rear Brake Adjuster and Shoe Lever Check................................................................................................. 542 Wheel Cylinder Removal and Installation.................................................................................................. 542 Wheel Cylinder Inspection................................................................................................................ 543 Brake Back Plate Removal and Installation................................................................................................ 543 Specifications............................................................................................................................... 544 Tightening Torque Specifications......................................................................................................... 544 Special Tools and Equipment.................................................................................................................. 544 Recommended Service Material............................................................................................................. 544 Disc............................................................................................................................................. 545 Repair Instructions.......................................................................................................................... 545 Rear Disc Brake Components............................................................................................................... 545 Rear Disc Brake Pad Removal and Installation............................................................................................. 546 Rear Disc Brake Caliper Removal and Installation......................................................................................... 547 Rear Disc Brake Pad Inspection........................................................................................................... 549 Rear Disc Brake Caliper Disassembly and Assembly......................................................................................... 549 Rear Disc Brake Caliper Check............................................................................................................ 551 Rear Brake Disc Removal and Installation................................................................................................. 551 Rear Brake Disc Inspection............................................................................................................... 552 Specifications............................................................................................................................... 552 Tightening Torque Specifications......................................................................................................... 552 Special Tools and Equipment.................................................................................................................. 553 Recommended Service Material............................................................................................................. 553 Special Tool............................................................................................................................. 553 Parking Brake........................................................................................................................................ 554 Repair Instructions.............................................................................................................................. 554 Parking Brake Cable Components............................................................................................................... 554 Parking Brake Inspection and Adjustment...................................................................................................... 555 Parking Brake Cable Removal and Installation................................................................................................. 556 Parking Brake Lever Removal and Installation................................................................................................. 556 Specifications................................................................................................................................... 557 Tightening Torque Specifications............................................................................................................. 557 ABS.................................................................................................................................................. 558 Precautions...................................................................................................................................... 558 Precautions in Diagnosing Troubles........................................................................................................... 558 Precautions in On-Vehicle Service............................................................................................................ 558 General Description.............................................................................................................................. 559 ABS Description.............................................................................................................................. 559 ABS Hydraulic Unit / Control Module Assembly Description..................................................................................... 560 CAN Communication System Description......................................................................................................... 560 Schematic and Routing Diagram.................................................................................................................... 561 ABS Schematic................................................................................................................................ 561 ABS Wiring Circuit Diagram................................................................................................................... 562 Component Location............................................................................................................................... 564 ABS Components Location...................................................................................................................... 564 Diagnostic Information and Procedures............................................................................................................ 564 ABS Check.................................................................................................................................... 564 ABS Warning Light Check...................................................................................................................... 566 EBD Warning Light (Brake Warning Light) Check................................................................................................ 566 DTC Check.................................................................................................................................... 567 DTC Table.................................................................................................................................... 567 DTC Clearance................................................................................................................................ 567 Scan Tool Data............................................................................................................................... 568 ABS Warning Light Does Not Come ON at Ignition Switch ON..................................................................................... 569 ABS Warning Light Comes ON Steady............................................................................................................ 570 EBD Warning Light (Brake Warning Light) Comes ON Steady...................................................................................... 571 Serial Data Link Circuit Check............................................................................................................... 572 DTC C1013: Control Module Mismatch........................................................................................................... 574 DTC C1015: G Sensor Circuit (4WD Model)...................................................................................................... 575 DTC 1016: Brake Light Switch................................................................................................................. 576 DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder............................ 577 DTC C1033: Wheel Speed Sensor Deviation...................................................................................................... 579 DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid................................................... 580 DTC C1057: Power Supply Voltage Too High / Too Low........................................................................................... 581 DTC C1061: Pump Motor Circuit................................................................................................................ 582 DTC C1063: Solenoid Valve Power Supply Driver Circuit........................................................................................ 583 DTC C1071: Control Module Internal Defect.................................................................................................... 584 ABS Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check.................................................................. 584 Repair Instructions.............................................................................................................................. 585 ABS Hydraulic Unit Operation Check........................................................................................................... 585 ABS Hydraulic Unit / Control Module Assembly Components...................................................................................... 586 ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection........................................................................... 587 ABS Hydraulic Unit / Control Module Assembly Removal and Installation........................................................................ 587 Front and Rear Wheel Speed Sensor On-Vehicle Inspection...................................................................................... 588 Front Wheel Speed Sensor Removal and Installation............................................................................................ 589 Front and Rear Wheel Speed Sensor Inspection................................................................................................. 590 Rear Wheel Speed Sensor Removal and Installation (4WD Model)................................................................................. 590 Rear Wheel Speed Sensor Removal and Installation (2WD Model)................................................................................. 590 Front Wheel Speed Sensor Encoder On-Vehicle Inspection....................................................................................... 591 Front Wheel Speed Sensor Encoder Removal and Installation.................................................................................... 591 Rear Wheel Speed Sensor Encoder On-Vehicle Inspection........................................................................................ 591 Rear Wheel Speed Sensor Encoder Removal and Installation..................................................................................... 591 G Sensor Removal and Installation (4WD Model)................................................................................................ 592 G Sensor Inspection (4WD Model).............................................................................................................. 592 Specifications................................................................................................................................... 593 Tightening Torque Specifications............................................................................................................. 593 Special Tools and Equipment...................................................................................................................... 593 Special Tool................................................................................................................................. 593 Transmission / Transaxle................................................................................................................................. 595 Precautions.......................................................................................................................................... 598 Precautions...................................................................................................................................... 598 Precautions on Transmission / Transaxle...................................................................................................... 598 Automatic Transmission/Transaxle..................................................................................................................... 599 Precautions...................................................................................................................................... 599 Precautions in Diagnosing Trouble............................................................................................................ 599 General Service Procedure Information........................................................................................................ 599 Precautions for Disassembly and Reassembly................................................................................................... 599 General Description.............................................................................................................................. 600 A/T Description.............................................................................................................................. 600 Clutch / Brake / Planetary Gear Function of Automatic Transaxle.............................................................................. 604 Table of Component Operation................................................................................................................. 605 Operation of Shift Solenoid Valves and TCC Solenoid Valve.................................................................................... 605 Automatic Gear Shift Table................................................................................................................... 605 Brake Interlock System Construction.......................................................................................................... 607 A/T Diagnosis General Description............................................................................................................ 607 On-Board Diagnostic System Description....................................................................................................... 608 CAN Communication System Description......................................................................................................... 608 Schematic and Routing Diagram.................................................................................................................... 609 Electronic Shift Control Input / Output Diagram.............................................................................................. 609 Transmission Control Module (TCM) Wiring Diagram............................................................................................. 610 Component Location............................................................................................................................... 611 Electronic Shift Control System Components Location.......................................................................................... 611 Diagnostic Information and Procedures............................................................................................................ 612 A/T System Check............................................................................................................................. 612 Visual Inspection............................................................................................................................ 614 Malfunction Indicator Lamp (MIL) Check....................................................................................................... 615 Transmission Warning Light Check (Non-Euro-OBD Model)........................................................................................ 615 DTC Table.................................................................................................................................... 615 DTC Check.................................................................................................................................... 617 DTC Clearance................................................................................................................................ 618 Fail Safe Table.............................................................................................................................. 618 Scan Tool Data............................................................................................................................... 619 A/T Basic Check.............................................................................................................................. 621 Road Test.................................................................................................................................... 622 Manual Road Test............................................................................................................................. 623 Stall Test................................................................................................................................... 624 Time Lag Test................................................................................................................................ 625 Line Pressure Test........................................................................................................................... 626 Engine Brake Test............................................................................................................................ 627 “P” Range Test............................................................................................................................... 627 A/T Symptom Diagnosis........................................................................................................................ 628 Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON (Non- Euro-OBD Model).............................. 631 Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON (Non-Euro- OBD Model).................................... 631 DTC P0705: Transmission Range Sensor Circuit Malfunction (P R N D L Input)................................................................... 632 DTC P0707: Transmission Range Sensor Circuit Low............................................................................................. 633 DTC P0711: Transmission Fluid Temperature Sensor “A” Circuit Range / Performance............................................................. 635 DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low............................................................................. 636 DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High............................................................................ 637 DTC P0717: Input Speed Sensor “A” Circuit No Signal.......................................................................................... 638 DTC P0722: Output Speed Sensor Circuit No Signal............................................................................................. 640 DTC P0741 / P0742: Torque Converter Clutch Circuit Performance or Stuck OFF / Stuck ON....................................................... 641 DTC P0751 / P0752: Shift Solenoid “A” Performance or Stuck OFF / Shift Solenoid “A” Stuck ON................................................. 642 DTC P0756 / P0757: Shift Solenoid “B” Performance or Stuck OFF / Shift Solenoid “B” Stuck ON................................................. 643 DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance................................................................. 644 DTC P0962: Pressure Control Solenoid “A” Control Circuit Low................................................................................. 645 DTC P0963: Pressure Control Solenoid “A” Control Circuit High................................................................................ 646 DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low........................................... 647 DTC P0974 / P0977: Shift Solenoid “A” Control Circuit High / Shift Solenoid “B” Control Circuit High......................................... 649 DTC P0602 / P1702: Control Module Programming Error / Internal Control Module Check Sum Error................................................ 650 DTC P1723: Range select switch malfunction................................................................................................... 651 DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High............................................................ 652 DTC P2764: Torque Converter Clutch Pressure Control Solenoid Control Circuit Low............................................................. 653 DTC U0073: Control Module Communication Bus Off.............................................................................................. 654 DTC U0100: Lost Communication with ECM....................................................................................................... 654 Inspection of TCM and Its Circuits........................................................................................................... 655 TCM Power and Ground Circuit Check........................................................................................................... 659 Brake Interlock System Inspection............................................................................................................ 661 Repair Instructions.............................................................................................................................. 662 A/T Fluid Level Check........................................................................................................................ 662 A/T Fluid Change............................................................................................................................. 662 Select Lever Components...................................................................................................................... 663 Select Lever Assembly Removal and Installation............................................................................................... 663 Select Lever Knob Installation............................................................................................................... 663 Select Lever Inspection...................................................................................................................... 663 “3” Position Switch Inspection............................................................................................................... 664 Shift Lock Solenoid Inspection............................................................................................................... 664 Shift Lock Solenoid Replacement.............................................................................................................. 664 Select Cable Components...................................................................................................................... 665 Select Cable Removal and Installation........................................................................................................ 665 Select Cable Adjustment...................................................................................................................... 665 Key Interlock Cable Removal and Installation................................................................................................. 666 Transmission Range Sensor Inspection and Adjustment.......................................................................................... 668 Output Shaft Speed Sensor Removal and Installation........................................................................................... 669 Output Shaft Speed Sensor Inspection......................................................................................................... 670 Input Shaft Speed Sensor Removal and Installation............................................................................................ 670 Input Shaft Speed Sensor Inspection.......................................................................................................... 670 Transmission Fluid Temperature Sensor Removal and Installation............................................................................... 670 Transmission Fluid Temperature Sensor Inspection............................................................................................. 671 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Pressure Control Solenoid Valve) Removal and Installation..................... 671 Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve) Inspection.................................................................... 673 Pressure Control Solenoid Valve Inspection................................................................................................... 675 Transmission Control Module (TCM) Removal and Installation................................................................................... 676 Differential Side Oil Seal Replacement....................................................................................................... 676 A/T Fluid Cooler Hoses Inspection............................................................................................................ 677 A/T Fluid Cooler Hoses Replacement........................................................................................................... 677 A/T Relay Inspection......................................................................................................................... 677 Automatic Transaxle Unit Components.......................................................................................................... 678 Automatic Transaxle Unit Dismounting and Remounting.......................................................................................... 678 Automatic Transaxle Assembly Components...................................................................................................... 680 Automatic Transaxle Unit Disassembly......................................................................................................... 683 Oil Pump 2nd Coast Brake and 2nd Brake Components............................................................................................ 690 2nd Coast Brake and 2nd Brake Preliminary Check.............................................................................................. 691 Oil Pump, 2nd Coast Brake and 2nd Brake Disassembly and Reassembly........................................................................... 691 Oil Pump, 2nd Brake and 2nd Coast Brake Inspection........................................................................................... 696 One-Way No. 1 Clutch Components.............................................................................................................. 698 One-Way No. 1 Clutch Operation Check......................................................................................................... 698 One-Way No. 1 Clutch Disassembly and Reassembly.............................................................................................. 698 One-Way No. 1 Clutch Inspection.............................................................................................................. 699 Forward and Direct Clutch Components......................................................................................................... 700 Forward and Direct Clutch Preliminary Check.................................................................................................. 701 Forward and Direct Clutch Disassembly and Reassembly......................................................................................... 701 Forward and Direct Clutch Inspection......................................................................................................... 705 1st / Reverse Brake and One-Way No. 2 Clutch Components...................................................................................... 706 1st / Reverse Brake and One-Way No. 2 Clutch Operation Check................................................................................. 707 1st / Reverse Brake and One-Way No. 2 Clutch Disassembly and Reassembly...................................................................... 707 1st / Reverse Brake and One-Way No. 2 Clutch Inspection...................................................................................... 708 Underdrive Clutch and One-Way No. 3 Clutch Components........................................................................................ 709 Underdrive Clutch and One-Way No. 3 Clutch Preliminary Check................................................................................. 710 Underdrive Clutch and One-Way No. 3 Clutch Operation Check................................................................................... 710 Underdrive Clutch and One-Way No. 3 Clutch Disassembly and Reassembly........................................................................ 710 Underdrive Clutch and One-Way No. 3 Clutch Inspection........................................................................................ 713 Planetary Gear Components.................................................................................................................... 714 Planetary Gear Disassembly and Reassembly.................................................................................................... 715 Planetary Gear Inspection.................................................................................................................... 715 Underdrive Brake Components.................................................................................................................. 716 Underdrive Brake Disassembly and Reassembly.................................................................................................. 716 Underdrive Brake Inspection.................................................................................................................. 717 Reduction Drive Gear Assembly Operation Check................................................................................................ 717 Underdrive Gear Assembly Components.......................................................................................................... 718 Underdrive Gear Preliminary Check............................................................................................................ 718 Valve Body Assembly Components............................................................................................................... 719 Valve Body Assembly Disassembly and Reassembly............................................................................................... 720 Differential Components...................................................................................................................... 721 Differential Preliminary Check............................................................................................................... 721 Differential Gear Assembly Removal and Installation.......................................................................................... 722 Transaxle Rear Cover Components.............................................................................................................. 724 Transaxle Rear Cover Disassembly and Reassembly.............................................................................................. 724 Transaxle Rear Cover Inspection.............................................................................................................. 725 Automatic Transaxle Unit Assembly............................................................................................................ 725 Specifications................................................................................................................................... 737 Bearing and Race Installation Specification.................................................................................................. 737 Tightening Torque Specifications............................................................................................................. 738 Special Tools and Equipment...................................................................................................................... 739 Recommended Service Material................................................................................................................. 739 Special Tool................................................................................................................................. 739 Manual Transmission/Transaxle........................................................................................................................ 741 General Description.............................................................................................................................. 741 Manual Transaxle Construction................................................................................................................ 741 Diagnostic Information and Procedures............................................................................................................ 746 Manual Transaxle Symptom Diagnosis........................................................................................................... 746 Repair Instructions.............................................................................................................................. 746 Manual Transaxle Oil Level Check............................................................................................................. 746 Manual Transaxle Oil Change.................................................................................................................. 747 Differential Side Oil Seal Replacement....................................................................................................... 748 Gear Shift Control Lever and Cable Components................................................................................................ 749 Gear Shift Control Lever and Cable Removal and Installation.................................................................................. 750 Gear Select Control Cable Adjustment......................................................................................................... 750 Back Up Light Switch Removal and Installation................................................................................................ 751 Back Up Light Switch Inspection.............................................................................................................. 751 Manual Transaxle Unit Components............................................................................................................. 752 Manual Transaxle Unit Dismounting and Remounting............................................................................................. 753 Gear Shift and Select Shaft Assembly Components.............................................................................................. 754 Gear Shift and Select Shaft Assembly Removal and Installation................................................................................ 755 Gear Shift and Select Shaft Assembly Disassembly and Reassembly.............................................................................. 756 Manual Transaxle Assembly Components......................................................................................................... 757 Fifth Gear Disassembly and Reassembly........................................................................................................ 758 Manual Transaxle Assembly Disassembly and Reassembly......................................................................................... 760 Right Case Disassembly and Reassembly........................................................................................................ 765 Left Case Disassembly and Reassembly......................................................................................................... 766 Input Shaft and Countershaft Components...................................................................................................... 768 Input Shaft Disassembly and Reassembly....................................................................................................... 769 Countershaft Disassembly and Reassembly...................................................................................................... 772 Gear Shift Shaft Components.................................................................................................................. 776 5th and Reverse Gear Shift Shafts Disassembly and Reassembly................................................................................. 776 Gear Shift Shaft and Fork Inspection......................................................................................................... 776 Differential Components...................................................................................................................... 777 Differential Disassembly and Reassembly...................................................................................................... 777 Specifications................................................................................................................................... 779 Tightening Torque Specifications............................................................................................................. 779 Special Tools and Equipment...................................................................................................................... 780 Recommended Service Material................................................................................................................. 780 Special Tool................................................................................................................................. 780 Clutch............................................................................................................................................... 783 General Description.............................................................................................................................. 783 Clutch (Hydraulic Type) Construction......................................................................................................... 783 Diagnostic Information and Procedures............................................................................................................ 784 Clutch System Symptom Diagnosis.............................................................................................................. 784 Repair Instructions.............................................................................................................................. 785 Clutch Pedal Inspection...................................................................................................................... 785 Clutch Fluid Level Inspection................................................................................................................ 785 Air Bleeding of Clutch System................................................................................................................ 786 Clutch Pedal Position (CPP) Switch Removal and Installation.................................................................................. 786 Clutch Pedal Position (CPP) Switch Inspection and Adjustment................................................................................. 787 Clutch Fluid Pipe and Hose Components........................................................................................................ 787 Clutch Fluid Pipe Removal and Installation................................................................................................... 788 Clutch Fluid Pipe Inspection................................................................................................................. 788 Clutch Master Cylinder Removal and Installation.............................................................................................. 788 Clutch Operating Cylinder Assembly Removal and Installation.................................................................................. 789 Clutch Operating Cylinder Assembly Inspection................................................................................................ 790 Clutch Cover, Clutch Disc and Flywheel Components............................................................................................ 790 Clutch Cover, Clutch Disc and Flywheel Removal and Installation.............................................................................. 791 Clutch Cover and Clutch Disc Inspection...................................................................................................... 793 Specifications................................................................................................................................... 793 Tightening Torque Specifications............................................................................................................. 793 Special Tools and Equipment...................................................................................................................... 794 Recommended Service Material................................................................................................................. 794 Special Tool................................................................................................................................. 794 Steering................................................................................................................................................. 795 Precautions.......................................................................................................................................... 797 Precautions...................................................................................................................................... 797 Precautions on Steering...................................................................................................................... 797 Steering General Diagnosis........................................................................................................................... 798 Precautions...................................................................................................................................... 798 Precautions for Steering Diagnosis........................................................................................................... 798 Diagnostic Information and Procedures............................................................................................................ 798 Steering Symptom Diagnosis................................................................................................................... 798 Steering System Inspection................................................................................................................... 799 Steering System Operation Check.............................................................................................................. 799 Steering Wheel and Column............................................................................................................................ 800 Precautions...................................................................................................................................... 800 Service Precautions of Steering Wheel and Column............................................................................................. 800 General Description.............................................................................................................................. 800 Steering Wheel and Column Construction....................................................................................................... 800 Diagnostic Information and Procedures............................................................................................................ 801 Checking Steering Column for Accident Damage................................................................................................. 801 Repair Instructions.............................................................................................................................. 802 Steering Wheel and Column Components......................................................................................................... 802 Steering Wheel Removal and Installation...................................................................................................... 803 Contact Coil Cable Assembly Removal and Installation......................................................................................... 804 Centering Contact Coil Cable Assembly........................................................................................................ 805 Contact Coil Cable Assembly Inspection....................................................................................................... 805 Steering Column Removal and Installation..................................................................................................... 805 Steering Column Inspection................................................................................................................... 807 Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)........................................................ 807 Steering Lock Assembly (Ignition Switch) Removal and Installation............................................................................ 808 Steering Lower Shaft Removal and Installation................................................................................................ 809 Specifications................................................................................................................................... 810 Tightening Torque Specifications............................................................................................................. 810 Special Tools and Equipment...................................................................................................................... 810 Special Tool................................................................................................................................. 810 Power Assisted Steering System....................................................................................................................... 811 Precautions...................................................................................................................................... 811 P/S System Note.............................................................................................................................. 811 Precautions in Diagnosing Troubles........................................................................................................... 811 General Description.............................................................................................................................. 812 P/S System Description....................................................................................................................... 812 EPS Diagnosis General Description............................................................................................................ 813 On-Board Diagnostic System Description....................................................................................................... 813 Schematic and Routing Diagram.................................................................................................................... 814 EPS System Wiring Circuit Diagram............................................................................................................ 814 Diagnostic Information and Procedures............................................................................................................ 815 EPS System Check............................................................................................................................. 815 “EPS” Warning Light Check.................................................................................................................... 818 DTC Check.................................................................................................................................... 818 DTC Clearance................................................................................................................................ 819 DTC Table.................................................................................................................................... 819 Visual Inspection............................................................................................................................ 821 Scan Tool Data............................................................................................................................... 822 P/S System Symptom Diagnosis................................................................................................................. 823 DLC and Its Communication Check (No communication to P/S Control Module)..................................................................... 824 “EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts..................................................... 826 “EPS” Warning Light Remains ON Steady after Engine Starts.................................................................................... 828 DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure..................................................................................... 829 DTC C1116: Steering Torque Sensor Power Supply Circuit....................................................................................... 831 DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure.............................................................................. 833 DTC C1122: Engine Speed Signal............................................................................................................... 835 DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure..................................................................................... 837 DTC C1153: P/S Control Module Power Supply Circuit........................................................................................... 838 DTC C1155: P/S Control Module Internal Failure............................................................................................... 839 P/S Control Module Power Supply and Ground Circuit Check..................................................................................... 840 Inspection of P/S Control Module and Its Circuits............................................................................................ 841 Steering Wheel Play Check.................................................................................................................... 845 Steering Force Check......................................................................................................................... 845 Repair Instructions.............................................................................................................................. 846 Steering Gear Case Assembly Components....................................................................................................... 846 Tie-Rod End Boot On-Vehicle Inspection....................................................................................................... 847 Tie-Rod End Removal and Installation......................................................................................................... 847 Tie-Rod End Initial Position Setting......................................................................................................... 848 Tie-Rod End Inspection....................................................................................................................... 848 Steering Shaft Joint On-Vehicle Inspection................................................................................................... 848 Steering Gear Case Assembly Removal and Installation......................................................................................... 849 Steering Rack Boot Inspection................................................................................................................ 850 Tie-Rod / Rack Boot Removal and Installation................................................................................................. 850 Steering Rack Plunger Removal and Installation............................................................................................... 851 Steering Rack Plunger Inspection............................................................................................................. 852 P/S Control Module Removal and Installation.................................................................................................. 852 Torque Sensor and Its Circuit Inspection..................................................................................................... 853 P/S Motor and Its Circuit Inspection......................................................................................................... 854 Specifications................................................................................................................................... 855 Tightening Torque Specifications............................................................................................................. 855 Special Tools and Equipment...................................................................................................................... 855 Recommended Service Material................................................................................................................. 855 Special Tool................................................................................................................................. 855 HVAC..................................................................................................................................................... 857 Precautions.......................................................................................................................................... 860 Precautions...................................................................................................................................... 860 Precautions on HVAC.......................................................................................................................... 860 Heater and Ventilation............................................................................................................................... 861 General Description.............................................................................................................................. 861 Heater and Ventilation Construction.......................................................................................................... 861 Schematic and Routing Diagram.................................................................................................................... 863 Heater and Ventilation Wiring Circuit Diagram................................................................................................ 863 Component Location............................................................................................................................... 863 Electronic Control System Components Location................................................................................................ 863 Diagnostic Information and Procedures............................................................................................................ 864 Heater and Ventilation Symptom Diagnosis..................................................................................................... 864 Repair Instructions.............................................................................................................................. 865 HVAC Unit Components......................................................................................................................... 865 HVAC Unit Removal and Installation (Non-A/C)................................................................................................. 865 Blower Motor Removal and Installation........................................................................................................ 865 Blower Motor Inspection...................................................................................................................... 865 Blower Motor Resistor Removal and Installation............................................................................................... 866 Blower Motor Resistor Inspection............................................................................................................. 866 Blower Motor Relay Inspection................................................................................................................ 867 HVAC Control Unit Components................................................................................................................. 867 HVAC Control Unit Removal and Installation................................................................................................... 868 Blower Speed Selector Inspection............................................................................................................. 870 Air Intake Selector Inspection............................................................................................................... 870 Air Intake Control Actuator Removal and Installation......................................................................................... 870 Air Intake Control Actuator Inspection....................................................................................................... 871 Center Ventilation Louver Removal and Installation........................................................................................... 872 Side Ventilation Louver Removal and Installation............................................................................................. 872 Rear Duct Removal and Installation (If Equipped)............................................................................................. 873 HVAC Air Filter Removal and Installation (If Equipped)....................................................................................... 873 HVAC Air Filter Inspection (If Equipped)..................................................................................................... 873 Air Conditioning System.............................................................................................................................. 874 Manual Type...................................................................................................................................... 874 Precautions.................................................................................................................................. 874 A/C System Caution....................................................................................................................... 874 Precautions on Servicing A/C System...................................................................................................... 874 General Description.......................................................................................................................... 875 Sub-Cool A/C System Description.......................................................................................................... 875 A/C Operation Description at ECM......................................................................................................... 876 Schematic and Routing Diagram................................................................................................................ 876 Manual A/C Electronic Input Output Diagram............................................................................................... 876 A/C System Air Flow Diagram.............................................................................................................. 877 A/C System Wiring Diagram................................................................................................................ 878 Component Location........................................................................................................................... 879 A/C System Major Components Location..................................................................................................... 879 Electronic Control System Components Location............................................................................................ 880 Diagnostic Information and Procedures........................................................................................................ 881 A/C System Performance Inspection........................................................................................................ 881 Trouble Diagnosis for Abnormal Pressure.................................................................................................. 884 A/C System Inspection at ECM............................................................................................................. 885 A/C System Symptom Diagnosis............................................................................................................. 886 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................... 888 Repair Instructions.......................................................................................................................... 890 Operation Procedure for Refrigerant Charge............................................................................................... 890 Condenser Cooling Fan Removal and Installation........................................................................................... 895 Condenser Cooling Fan Inspection......................................................................................................... 896 Condenser Assembly On-Vehicle Inspection................................................................................................. 896 Condenser Assembly Removal and Installation.............................................................................................. 896 Desiccant Removal and Installation....................................................................................................... 897 HVAC Unit Components..................................................................................................................... 898 HVAC Unit Removal and Installation....................................................................................................... 899 Evaporator Inspection.................................................................................................................... 900 Evaporator Temperature Sensor Removal and Installation................................................................................... 900 Evaporator Temperature Sensor Inspection................................................................................................. 901 Expansion Valve Removal and Installation................................................................................................. 901 Expansion Valve Inspection............................................................................................................... 901 A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................................................... 902 A/C Refrigerant Pressure Sensor Removal and Installation................................................................................. 902 A/C Switch Inspection.................................................................................................................... 902 A/C System Relay Inspection.............................................................................................................. 903 Compressor Drive Belt Inspection and Adjustment.......................................................................................... 903 Compressor Drive Belt Removal and Installation........................................................................................... 903 Compressor Assembly Removal and Installation............................................................................................. 903 Compressor Assembly Components........................................................................................................... 904 Magnet Clutch Inspection................................................................................................................. 905 Magnet Clutch Removal and Installation................................................................................................... 905 Thermal Switch Inspection................................................................................................................ 907 Thermal Switch Removal and Installation.................................................................................................. 907 Relief Valve Inspection.................................................................................................................. 907 Relief valve Removal and Installation.................................................................................................... 908 Specifications............................................................................................................................... 908 Tightening Torque Specifications......................................................................................................... 908 Special Tools and Equipment.................................................................................................................. 909 Recommended Service Material............................................................................................................. 909 Special Tool............................................................................................................................. 909 Automatic Type................................................................................................................................... 910 Precautions.................................................................................................................................. 910 A/C System Caution....................................................................................................................... 910 Precautions in Diagnosing Trouble........................................................................................................ 910 Precautions on Servicing A/C System...................................................................................................... 910 General Description.......................................................................................................................... 910 Auto A/C System Description.............................................................................................................. 910 HVAC Control Description................................................................................................................. 911 Sub-Cool A/C System Description.......................................................................................................... 911 On-Board Diagnostic System Description................................................................................................... 911 Schematic and Routing Diagram................................................................................................................ 912 Auto A/C Electronic Control Input / Output Diagram....................................................................................... 912 A/C System Air Flow Diagram.............................................................................................................. 912 A/C System Wiring Diagram................................................................................................................ 913 Component Location........................................................................................................................... 915 A/C System Major Components Location..................................................................................................... 915 Electronic Control System Components Location............................................................................................ 915 Diagnostic Information and Procedures........................................................................................................ 916 Air Conditioning System Check............................................................................................................ 916 A/C System Symptom Diagnosis............................................................................................................. 918 Abnormal Noise Symptom Diagnosis of A/C System........................................................................................... 920 DTC Check................................................................................................................................ 920 DTC Clearance............................................................................................................................ 922 DTC Table................................................................................................................................ 922 Fail-Safe Table.......................................................................................................................... 925 Scan Tool Data........................................................................................................................... 926 Visual Inspection........................................................................................................................ 928 DTC B1502: Inside Air Temperature Sensor Circuit Malfunction............................................................................. 928 DTC B1503: Evaporator Temperature Sensor Circuit Malfunction............................................................................. 930 DTC B1504: Sunload Sensor Circuit Malfunction............................................................................................ 931 DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction................................................. 932 DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction.................................................... 934 DTC B1513: Temperature Control Actuator (Motor) and/or Its Circuit Malfunction........................................................... 936 DTC B1514: Air Flow Control Actuator (Motor) and/or Its Circuit Malfunction.............................................................. 938 DTC B1520 / B1521 / B1522: Temperature / Blower Speed / Air Flow Selector Malfunction.................................................... 939 DTC B1541: Back-Up Power Supply Circuit Malfunction...................................................................................... 940 DTC B1546: A/C Refrigerant Pressure Malfunction.......................................................................................... 941 DTC B1551: Serial Communication Circuit Malfunction...................................................................................... 941 DTC B1552: HVAC Control Module Check Sum Error........................................................................................... 943 DTC B1553: CAN Communication Circuit Malfunction......................................................................................... 943 DTC B1557: VSS Signal Failure............................................................................................................ 944 DTC B1561: ECT Signal Failure............................................................................................................ 944 DTC B1562: Outside Air Temperature Signal Failure........................................................................................ 945 DTC B1563: A/C Refrigerant Pressure Signal Failure....................................................................................... 945 DTC B1570: Engine Type Signal Failure.................................................................................................... 946 DTC B1571: Combination Meter Spec Signal Failure......................................................................................... 946 Inspection of HVAC Control Module and Its Circuit........................................................................................ 947 A/C System Inspection at ECM............................................................................................................. 950 Repair Instructions.......................................................................................................................... 951 Operation Procedure for Refrigerant Charge............................................................................................... 951 HVAC Unit Components..................................................................................................................... 951 HVAC Unit Removal and Installation....................................................................................................... 952 Temperature Control Actuator Removal and Installation.................................................................................... 952 Temperature Control Actuator and Its Circuit Inspection.................................................................................. 952 Air Flow Control Actuator Removal and Installation....................................................................................... 954 Air Flow Control Actuator and Its Circuit Inspection..................................................................................... 954 Air Intake Actuator Removal and Installation............................................................................................. 955 Air Intake Actuator Inspection........................................................................................................... 955 Actuator Linkage Inspection.............................................................................................................. 955 Blower Motor Controller Removal and Installation......................................................................................... 955 Blower Motor Controller Inspection....................................................................................................... 956 HVAC Control Module Removal and Installation............................................................................................. 956 Sunload Sensor Removal and Installation.................................................................................................. 956 Sunload Sensor Inspection................................................................................................................ 957 Outside Air Temperature Sensor Removal and Installation.................................................................................. 957 Outside Air Temperature Sensor Inspection................................................................................................ 957 Inside Air Temperature Sensor Removal and Installation................................................................................... 957 Inside Air Temperature Sensor Inspection................................................................................................. 957 Condenser Cooling Fan Relay Inspection................................................................................................... 958 Condenser Cooling Fan Removal and Installation........................................................................................... 958 Condenser Cooling Fan Inspection......................................................................................................... 958 Condenser Assembly On-Vehicle Inspection................................................................................................. 958 Condenser Assembly Removal and Installation.............................................................................................. 958 Evaporator Inspection.................................................................................................................... 958 Evaporator Temperature Sensor Removal and Installation................................................................................... 958 Evaporator Temperature Sensor Inspection................................................................................................. 958 Expansion Valve Removal and Installation................................................................................................. 958 Expansion Valve Inspection............................................................................................................... 958 A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................................................... 958 A/C Refrigerant Pressure Sensor Removal and Installation................................................................................. 958 Compressor Relay Inspection.............................................................................................................. 958 Compressor Drive Belt Inspection and Adjustment.......................................................................................... 958 Compressor Drive Belt Removal and Installation........................................................................................... 958 Compressor Assembly Removal and Installation............................................................................................. 958 Compressor Assembly Components........................................................................................................... 958 Magnet Clutch Removal and Installation................................................................................................... 958 Magnet Clutch Inspection................................................................................................................. 958 Thermal Switch Inspection................................................................................................................ 958 Thermal Switch Removal and Installation.................................................................................................. 958 Relief Valve Inspection.................................................................................................................. 958 Special Tools and Equipment.................................................................................................................. 959 Recommended Service Material............................................................................................................. 959 Special Tool............................................................................................................................. 959 Restraint................................................................................................................................................ 961 Precautions.......................................................................................................................................... 963 Precautions...................................................................................................................................... 963 Precautions on Restraint..................................................................................................................... 963 Seat Belts........................................................................................................................................... 964 Precautions...................................................................................................................................... 964 Precautions on Service and Diagnosis of Seat Belt............................................................................................ 964 General Description.............................................................................................................................. 965 Seat Belt Construction....................................................................................................................... 965 Diagnostic Information and Procedures............................................................................................................ 967 Repair and Inspection Required after Accident................................................................................................ 967 Repair Instructions.............................................................................................................................. 968 Front Seat Belt Components................................................................................................................... 968 Front Seat Belt Removal and Installation..................................................................................................... 969 Front Seat Belt Inspection................................................................................................................... 970 Rear Seat Belt Components.................................................................................................................... 971 Rear Seat Belt Removal and Installation...................................................................................................... 973 Rear Seat Belt Inspection.................................................................................................................... 973 Specifications................................................................................................................................... 973 Tightening Torque Specifications............................................................................................................. 973 Air Bag System....................................................................................................................................... 974 Precautions...................................................................................................................................... 974 Precautions on Service and Diagnosis of Air Bag System....................................................................................... 974 Precautions on Handling and Storage of Air Bag System Components............................................................................. 974 Precautions on Disposal of Air Bag and Seat Belt Pretensioner................................................................................ 978 General Description.............................................................................................................................. 978 Air Bag System Construction.................................................................................................................. 978 Air Bag System Input / Output Table.......................................................................................................... 979 Schematic and Routing Diagram.................................................................................................................... 980 Air Bag System Wiring Circuit Diagram........................................................................................................ 980 Air Bag System Input / Output Diagram........................................................................................................ 982 Component Location............................................................................................................................... 983 Air Bag System Components, Wiring and Connectors Location.................................................................................... 983 Diagnostic Information and Procedures............................................................................................................ 984 Air Bag Diagnostic System Check.............................................................................................................. 984 Air Bag Diagnostic System Check Flow......................................................................................................... 985 DTC Table.................................................................................................................................... 986 DTC Check.................................................................................................................................... 990 DTC Clearance................................................................................................................................ 990 Scan Tool Data............................................................................................................................... 990 “AIR BAG” Warning Light Comes ON Steady...................................................................................................... 991 “AIR BAG” Warning Light Does Not Come ON..................................................................................................... 994 Serial Data Link Circuit Check............................................................................................................... 995 DTC B1013: SDM Internal Failure.............................................................................................................. 997 DTC B1014: “AIR BAG” Warning Light Circuit................................................................................................... 998 DTC B1016: Power Supply Voltage too High..................................................................................................... 998 DTC B1017: Power Supply Voltage too Low...................................................................................................... 999 DTC B1021: Front Air Bag Deployment Record...................................................................................................1000 DTC B1024 / B1025: Side Air-Bag Deployment Record............................................................................................1001 DTC B1026: Seat Belt Pretensioner Activation Record..........................................................................................1001 DTC B1027: Number of Deployment Times Exceeded Limit.........................................................................................1002 DTC B1031: Driver Air Bag Circuit High Resistance............................................................................................1003 DTC B1032: Driver Air Bag Circuit Low Resistance.............................................................................................1005 DTC B1033: Driver Air Bag Circuit Shorted to Ground..........................................................................................1007 DTC B1034: Driver Air Bag Circuit Shorted to Power Supply....................................................................................1009 DTC B1041: Passenger Air Bag Circuit High Resistance.........................................................................................1012 DTC B1042: Passenger Air Bag Circuit Low Resistance..........................................................................................1015 DTC B1043: Passenger Air Bag Circuit Shorted to Ground.......................................................................................1017 DTC B1044: Passenger Air Bag Circuit Shorted to Power Supply.................................................................................1018 DTC B1051 / B1055: Seat Belt Pretensioner Circuit High Resistance............................................................................1020 DTC B1052 / B1056: Seat Belt Pretensioner Circuit Low Resistance.............................................................................1023 DTC B1053 / B1057: Seat Belt Pretensioner Shorted to Ground..................................................................................1024 DTC B1054 / B1058: Seat Belt Pretensioner Circuit Shorted to Power Supply....................................................................1026 DTC B1061 / B1065: Side-Air Bag Circuit High Resistance......................................................................................1027 DTC B1062 / B1066: Side-Air Bag Circuit Low Resistance.......................................................................................1031 DTC B1063 / B1067: Side-Air Bag Circuit Shorted to Ground....................................................................................1033 DTC B1064 / B1068: Side-Air Bag Circuit Shorted to Power Supply..............................................................................1036 DTC B1071: Driver Forward Impact-Sensor Communication Data Inconsistent......................................................................1038 DTC B1072: Driver Forward Impact-Sensor Communication Data Invalid...........................................................................1038 DTC B1073: Driver Forward Impact-Sensor Circuit Shorted to Ground............................................................................1039 DTC B1074: Driver Forward Impact-Sensor Circuit Open.........................................................................................1040 DTC B1081 / B1091: Side Impact-Sensor No Response............................................................................................1042 DTC B1082 / B1092: Side Impact-Sensor Communication DATA Invalid.............................................................................1042 DTC B1083 / B1093: Side Impact-Sensor Circuit Shorted to Ground..............................................................................1043 DTC B1084 / B1094: Side Impact-Sensor Circuit Open...........................................................................................1045 DTC B1085 / B1095: Side Impact-Sensor Communication DATA Inconsistent........................................................................1046 DTC B1361 / B1365: Curtain-Air Bag Circuit High Resistance...................................................................................1047 DTC B1362 / B1366: Curtain-Air Bag Circuit Low Resistance....................................................................................1050 DTC B1363 / B1367: Curtain-Air Bag Circuit Shorted to Ground.................................................................................1053 DTC B1364 / B1368: Curtain-Air Bag Circuit Shorted to Power Supply...........................................................................1055 SDM Power Supply and Ground Circuit Check....................................................................................................1057 Contact Coil Cable and Its Circuit Check.....................................................................................................1059 Inspection of Intermittent and Poor Connections..............................................................................................1062 Repair and Inspection Required after Accident................................................................................................1063 Repair Instructions..............................................................................................................................1066 Disabling Air Bag System.....................................................................................................................1066 Enabling Air Bag System......................................................................................................................1067 SDM Removal and Installation.................................................................................................................1067 SDM Inspection...............................................................................................................................1069 Driver Air Bag (Inflator) Module Removal and Installation....................................................................................1069 Driver Air Bag (Inflator) Module Inspection..................................................................................................1070 Passenger Air Bag (Inflator) Module Removal and Installation.................................................................................1070 Passenger Air Bag (Inflator) Module Inspection...............................................................................................1072 Side-Air Bag (Inflator) Module Removal and Installation......................................................................................1073 Side-Air Bag (Inflator) Inspection...........................................................................................................1075 Side Curtain-Air Bag (Inflator) Module Removal and Installation..............................................................................1075 Side Curtain-Air Bag (Inflator) Module Inspection............................................................................................1077 Forward Impact-Sensor Removal and Installation...............................................................................................1077 Forward Impact-Sensor Inspection.............................................................................................................1078 Side Impact-Sensor Removal and Installation..................................................................................................1079 Side Impact-Sensor Inspection................................................................................................................1079 Passenger Air Bag (Inflator) Module Repair Harness Installation..............................................................................1080 Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal................................................................................1081 Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal.............................................................1091 Specifications...................................................................................................................................1092 Tightening Torque Specifications.............................................................................................................1092 Special Tools and Equipment......................................................................................................................1092 Use of Special Tools.........................................................................................................................1092 Special Tool.................................................................................................................................1094 Body, Cab and Accessories................................................................................................................................1095 Precautions..........................................................................................................................................1101 Precautions......................................................................................................................................1101 Precautions on Body, Cab and Accessories.....................................................................................................1101 Precautions for Body Service.................................................................................................................1101 Fastener Caution for Body Service............................................................................................................1101 Wiring Systems.......................................................................................................................................1102 Precautions......................................................................................................................................1102 Cautions in Body Electrical System Servicing.................................................................................................1102 General Description..............................................................................................................................1102 Abbreviations................................................................................................................................1102 Wire / Connector Color Symbols...............................................................................................................1102 Symbols and Marks............................................................................................................................1103 How to Read Connector Layout Diagram.........................................................................................................1105 How to Read Connector Codes and Terminal Nos.................................................................................................1106 How to Read Ground Point.....................................................................................................................1109 How to Read Power Supply Diagram.............................................................................................................1110 How to Read System Circuit Diagram...........................................................................................................1110 Connector Layout Diagram.........................................................................................................................1112 Connector Layout Diagram.....................................................................................................................1112 Engine Compartment...........................................................................................................................1112 Instrument Panel.............................................................................................................................1123 Door, Roof...................................................................................................................................1129 Floor........................................................................................................................................1133 Rear.........................................................................................................................................1142 Ground Point.....................................................................................................................................1144 Ground (earth) Point.........................................................................................................................1144 Power Supply Diagram.............................................................................................................................1145 Power Supply Diagram.........................................................................................................................1145 Fuses and the Protected Parts................................................................................................................1147 Fuses in Main Fuse Box.......................................................................................................................1147 Individual Circuit Fuse Box No. 1............................................................................................................1148 Individual Circuit Fuse Box No. 2 (In J/B (Except Taiwan))...................................................................................1149 Individual Circuit Fuse Box No. 2 (In J/B (Taiwan))..........................................................................................1151 Individual Circuit Fuse Box No.3 (Sedan).....................................................................................................1153 Junction Block (J/B) Connector / Fuse Layout.................................................................................................1154 Junction Block Inner Circuit (Overview (Except Taiwan))......................................................................................1155 Junction Block Inner Circuit (Detail (Except Taiwan))........................................................................................1157 Junction Block Inner Circuit (Overview (Taiwan)).............................................................................................1162 Junction Block Inner Circuit (Detail (Taiwan))...............................................................................................1164 System Circuit Diagram...........................................................................................................................1169 System Circuit Diagram.......................................................................................................................1169 A-1 Cranking System Circuit Diagram..........................................................................................................1171 A-2 Charging System Circuit Diagram..........................................................................................................1172 A-3 Ignition System Circuit Diagram (M15A engine, M16A engine)...............................................................................1173 A-3 Ignition System Circuit Diagram (J20A engine)............................................................................................1174 A-4 Cooling System Circuit Diagram (M15A engine, M16A engine)................................................................................1175 A-4 Cooling System Circuit Diagram (J20A engine).............................................................................................1176 A-5 Engine and A/C Control System Circuit Diagram (M15A engine)..............................................................................1177 A-5 Engine and A/C Control System Circuit Diagram (M16A engine)..............................................................................1181 A-5 Engine and A/C Control System Circuit Diagram (J20A engine)..............................................................................1185 A-6 A/T Control System Circuit Diagram.......................................................................................................1189 A-7 Immobilizer System Circuit Diagram.......................................................................................................1191 A-8 Body Control System Circuit Diagram (Except Taiwan)......................................................................................1192 A-8 Body Control System Circuit Diagram (Taiwan).............................................................................................1196 A-10 4WD Control System (Except Taiwan)......................................................................................................1200 B-1 Windshield Wiper and Washer Circuit Diagram..............................................................................................1201 B-2 Rear Wiper and Washer Circuit Diagram (Except Taiwan)....................................................................................1202 B-2 Rear Wiper and Washer Circuit Diagram (Taiwan)...........................................................................................1203 B-3 Rear Defogger Circuit Diagram (Hatchback (Except Taiwan))................................................................................1204 B-3 Rear Defogger Circuit Diagram (Hatchback (Taiwan)).......................................................................................1205 B-3 Rear Defogger Circuit Diagram (Sedan)....................................................................................................1206 B-4 Power Window Circuit Diagram.............................................................................................................1207 B-5 Power Door Lock Circuit Diagram (Except Taiwan)..........................................................................................1209 B-5 Power Door Lock Circuit Diagram (Taiwan).................................................................................................1211 B-6 Power Mirror Circuit Diagram (Hatchback (Except Taiwan)).................................................................................1213 B-6 Power Mirror Circuit Diagram (Hatchback (Taiwan))........................................................................................1214 B-6 Power Mirror Circuit Diagram (Sedan (Except Taiwan)).....................................................................................1215 B-6 Power Mirror Circuit Diagram (Sedan (Taiwan))............................................................................................1216 B-7 Horn Circuit Diagram.....................................................................................................................1217 B-8 Seat Heater Circuit Diagram..............................................................................................................1218 B-9 Keyless Start System Circuit Diagram.....................................................................................................1219 C-1 Combination Meter Circuit Diagram (Meter)................................................................................................1220 C-2 Combination Meter Circuit Diagram (Indicator)............................................................................................1221 C-3 Combination Meter Circuit Diagram (Warning Light)........................................................................................1222 D-1 Headlight System Circuit Diagram (Except Taiwan).........................................................................................1224 D-1 Headlight System Circuit Diagram (Taiwan)................................................................................................1226 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Hatchback (Except Taiwan))................................................1227 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Sedan (Except Taiwan))....................................................1228 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Hatchback (Taiwan)).......................................................1229 D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Sedan (Taiwan))...........................................................1230 D-3 Front Fog Light System Circuit Diagram (Except Taiwan)...................................................................................1231 D-3 Front Fog Light System Circuit Diagram (Taiwan)..........................................................................................1232 D-4 Illumination Light System Circuit Diagram (Except Taiwan)................................................................................1233 D-4 Illumination Light System Circuit Diagram (Taiwan).......................................................................................1234 D-5 Interior Light System Circuit Diagram (Hatchback (Except Taiwan))........................................................................1235 D-5 Interior Light System Circuit Diagram (Hatchback (Taiwan))...............................................................................1236 D-5 Interior Light System Circuit Diagram (Sedan (Except Taiwan))............................................................................1237 D-5 Interior Light System Circuit Diagram (Sedan (Taiwan))...................................................................................1238 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Hatchback (Except Taiwan))..................................................1239 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Sedan (Except Taiwan))......................................................1241 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Hatchback (Taiwan)).........................................................1243 D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Sedan (Taiwan)).............................................................1245 D-7 Brake Light System Circuit Diagram (Hatchback)...........................................................................................1247 D-7 Brake Light System Circuit Diagram (Sedan)...............................................................................................1248 D-8 Back-Up Light System Circuit Diagram (Hatchback).........................................................................................1249 D-8 Back-Up Light System Circuit Diagram (Sedan).............................................................................................1250 D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling).........................................................................1251 D-10 Rear Fog Light Circuit Diagram (Hatchback)..............................................................................................1252 D-10 Rear Fog Light Circuit Diagram (Sedan)..................................................................................................1253 E-1 Heater System Circuit Diagram............................................................................................................1254 E-2 Auto A/C System Circuit Diagram..........................................................................................................1256 F-1 Air-Bag System Circuit Diagram (4ch).....................................................................................................1258 F-1 Air-Bag System Circuit Diagram (8ch).....................................................................................................1259 F-2 Anti-Lock Brake System Circuit Diagram...................................................................................................1261 F-3 Electronic Stability Program System Circuit Diagram......................................................................................1263 F-4 Power Steering System Circuit Diagram....................................................................................................1265 G-1 Audio System Circuit Diagram.............................................................................................................1267 G-2 Multi Information Display / Accessory Socket System Circuit Diagram......................................................................1269 G-4 Navigation System Circuit Diagram........................................................................................................1270 List of Connector................................................................................................................................1272 List of Connectors...........................................................................................................................1272 C Connector..................................................................................................................................1272 E Connector..................................................................................................................................1273 G Connector..................................................................................................................................1275 J Connector..................................................................................................................................1277 K Connector..................................................................................................................................1278 L Connector..................................................................................................................................1278 M Connector (Sedan)..........................................................................................................................1281 O Connector (Hatchback)......................................................................................................................1281 Q Connector (8ch)............................................................................................................................1281 R Connector..................................................................................................................................1282 S Connector..................................................................................................................................1282 Lighting Systems.....................................................................................................................................1283 Precautions......................................................................................................................................1283 Precautions for Discharge Headlight Service (If Equipped)....................................................................................1283 Precautions in Diagnosing Troubles (Headlight Auto Leveling System)..........................................................................1283 General Description..............................................................................................................................1284 Discharge Headlight Description (If Equipped)................................................................................................1284 Headlight Auto Leveling System Description (If Equipped).....................................................................................1285 Auto-On Headlight System Description (If Equipped)...........................................................................................1287 Schematic and Routing Diagram....................................................................................................................1288 Headlight Auto Leveling System Wiring Circuit Diagram........................................................................................1288 Component Location...............................................................................................................................1288 Lighting System Components Location..........................................................................................................1288 Interior Light System Location...............................................................................................................1290 Diagnostic Information and Procedures............................................................................................................1290 Self-Diagnosis Function for Headlight Auto Leveling System...................................................................................1290 Headlight Leveling Warning Light Check.......................................................................................................1291 Headlight Symptom Diagnosis (Discharge Headlight Model)......................................................................................1291 Headlight Symptom diagnosis (Other than Discharge Headlight Model)...........................................................................1292 Auto-On Headlight System Symptom Diagnosis (If Equipped).....................................................................................1292 DRL System Symptom Diagnosis (If Equipped)...................................................................................................1293 Headlight Auto Leveling System Symptom Diagnosis (If Equipped)...............................................................................1293 Headlight Manual Leveling System Symptom Diagnosis (If Equipped).............................................................................1294 Turn Signal and Hazard Warning Light Symptom Diagnosis.......................................................................................1294 Clearance, Tail and License Plate Light Symptom Diagnosis....................................................................................1295 Back-Up Light Symptom Diagnosis..............................................................................................................1295 Brake Light Symptom Diagnosis................................................................................................................1295 Front Fog Light Symptom Diagnosis (If Equipped)..............................................................................................1295 Rear Fog Light Symptom Diagnosis (If Equipped)...............................................................................................1296 Illumination Cancel System Symptom Diagnosis (If Equipped)...................................................................................1296 Interior Light Symptom Diagnosis.............................................................................................................1296 DRL Operation Inspection (If Equipped).......................................................................................................1296 Inspection of DRL Controller and Its Circuits (If Equipped)..................................................................................1297 Auto-On Headlight Operation Inspection (If Equipped).........................................................................................1298 Inspection of Auto-On Headlight Controller and Its Circuit (If Equipped).....................................................................1298 Inspection of Headlight Leveling Control Module and Its Circuit (Headlight Auto Leveling System).............................................1299 Repair Instructions..............................................................................................................................1301 Headlight Housing Removal and Installation...................................................................................................1301 Headlight Bulb Replacement (Discharge Headlight Model).......................................................................................1302 Ballast Removal and Installation (Discharge Headlight Model).................................................................................1303 Igniter Removal and Installation (Discharge Headlight Model).................................................................................1303 Headlight Aiming Adjustment with Screen......................................................................................................1304 Headlight Switch (in Lighting Switch) Removal and Installation...............................................................................1306 Headlight Switch (in Lighting Switch) Inspection.............................................................................................1306 Hazard Warning Switch Removal and Installation...............................................................................................1307 Hazard Warning Switch Inspection.............................................................................................................1307 Brake Light Switch Inspection................................................................................................................1307 Turn Signal Light Switch (in Lighting Switch) Removal and Installation.......................................................................1307 Turn Signal Light Switch (in Lighting Switch) Inspection.....................................................................................1308 Turn Signal and Hazard Warning Relay Removal and Installation................................................................................1308 Turn Signal and Hazard Warning Relay Inspection..............................................................................................1309 License Light Assembly Removal and Installation (Hatchback)..................................................................................1309 License Light Removal and Installation (Sedan)...............................................................................................1310 Front Fog Light Assembly Removal and Installation (If Equipped)..............................................................................1310 Front Fog Light Switch Inspection (If Equipped)..............................................................................................1311 Front Fog Light Aiming Adjustment with Screen (If Equipped)..................................................................................1311 Rear Fog Light Switch Inspection (If Equipped)...............................................................................................1312 Headlight Manual Levering Switch Inspection (If Equipped)....................................................................................1313 Headlight Leveling Actuator Inspection (If Equipped).........................................................................................1313 Height Sensor Removal and Installation (If Equipped).........................................................................................1314 Height Sensor and Its Circuit Inspection (If Equipped).......................................................................................1315 Headlight Leveling Control Module Removal and Installation (If Equipped).....................................................................1315 Initialization of Headlight Auto Leveling System.............................................................................................1315 Auto-On Headlight Sensor Inspection (If Equipped)............................................................................................1316 Illumination Cancel Switch Inspection (If Equipped)..........................................................................................1317 Tail Light Relay, Headlight Relay, Front Fog Light Relay Inspection (If Equipped)............................................................1317 Specifications...................................................................................................................................1318 Tightening Torque Specifications.............................................................................................................1318 Instrumentation / Driver Info. / Horn................................................................................................................1319 Precautions......................................................................................................................................1319 Precautions in Diagnosing Troubles for Combination Meter.....................................................................................1319 General Description..............................................................................................................................1319 CAN Communication System Description.........................................................................................................1319 Auto Volume Control System Description (If Equipped).........................................................................................1321 Schematic and Routing Diagram....................................................................................................................1322 Combination Meter Circuit Diagram............................................................................................................1322 Component Location...............................................................................................................................1324 Audio System Component Location..............................................................................................................1324 Diagnostic Information and Procedures............................................................................................................1325 Speedometer and VSS Symptom Diagnosis........................................................................................................1325 Tachometer Symptom Diagnosis.................................................................................................................1325 Engine Coolant Temperature (ECT) Meter Symptom Diagnosis.....................................................................................1325 Fuel Meter Symptom Diagnosis.................................................................................................................1325 Low Fuel Warning Light Symptom Diagnosis.....................................................................................................1326 Oil Pressure Warning Light Symptom Diagnosis.................................................................................................1326 Brake and Parking Brake Warning Light Symptom Diagnosis......................................................................................1327 Seat Belt Reminder Light Symptom Diagnosis...................................................................................................1327 A/T Shift Position Indicator Symptom Diagnosis (A/T Model)...................................................................................1327 Charge Warning Light Symptom Diagnosis.......................................................................................................1328 Main Beam (High Beam) Indicator Symptom Diagnosis............................................................................................1328 Warning Buzzer Circuit Symptom Diagnosis.....................................................................................................1328 Cigarette Lighter Symptom Diagnosis (If Equipped)............................................................................................1329 Horn Symptom Diagnosis.......................................................................................................................1329 Information Display Symptom Diagnosis (If Equipped)..........................................................................................1329 Clock System Diagnosis (If Equipped).........................................................................................................1330 Audio System Symptom Diagnosis (If Equipped).................................................................................................1331 Remote Audio Control Switch Symptom Diagnosis (If Equipped)..................................................................................1333 Navigation Symptom Diagnosis (If Equipped)...................................................................................................1333 Repair Instructions..............................................................................................................................1333 Ignition Switch Removal and Installation.....................................................................................................1333 Ignition Switch Inspection...................................................................................................................1334 Combination Meter Removal and Installation...................................................................................................1334 Fuel Level Sensor Removal and Installation...................................................................................................1335 Fuel Level Sensor Inspection.................................................................................................................1335 Oil Pressure Switch Removal and Installation.................................................................................................1335 Oil Pressure Switch Inspection...............................................................................................................1335 Engine Coolant Temperature (ECT) Sensor Inspection...........................................................................................1335 Brake Fluid Level Switch Inspection..........................................................................................................1335 Parking Brake Switch Inspection..............................................................................................................1336 Door Switch (Front / Rear Door) Inspection...................................................................................................1336 Rear End Door Switch Inspection (Hatchback)..................................................................................................1336 Trunk Lid Switch Inspection (Sedan)..........................................................................................................1336 Outside Air Temperature Sensor Removal and Installation (If Equipped)........................................................................1337 Outside Air Temperature Sensor Inspection (If Equipped)......................................................................................1337 Instrument Panel Removal and Installation....................................................................................................1337 Information Display (Clock) Removal and Installation.........................................................................................1338 Audio Unit Removal and Installation (If Equipped)............................................................................................1339 Front Speaker Removal and Installation (If Equipped).........................................................................................1339 Rear Speaker Removal and Installation (If Equipped)..........................................................................................1339 GPS Antenna Removal and Installation (If Equipped)...........................................................................................1340 Horn Removal and Installation................................................................................................................1340 Horn Inspection..............................................................................................................................1340 Horn Relay Inspection........................................................................................................................1340 Antenna Base Removal and Installation (Hatchback)............................................................................................1341 Remote Audio Control Switch Removal and Installation (If Equipped)...........................................................................1341 Remote Audio Control Switch Inspection (If Equipped).........................................................................................1342 Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...............................................................................1342 Specifications...................................................................................................................................1342 Tightening Torque Specifications.............................................................................................................1342 Wipers / Washers.....................................................................................................................................1343 Diagnostic Information and Procedures............................................................................................................1343 Front Wiper and Washer Symptom Diagnosis.....................................................................................................1343 Rear Wiper and Washer Symptom Diagnosis......................................................................................................1343 Repair Instructions..............................................................................................................................1344 Wipers and Washers Components................................................................................................................1344 Washer Tank and Washer Pump Removal and Installation.........................................................................................1345 Washer Pump Inspection.......................................................................................................................1345 Windshield Wiper Removal and Installation....................................................................................................1345 Windshield Wiper Motor Inspection............................................................................................................1346 Rear Wiper Removal and Installation..........................................................................................................1348 Rear Wiper Motor Inspection..................................................................................................................1349 Windshield Wiper and Washer Switch Removal and Installation..................................................................................1350 Windshield Wiper and Washer Switch Inspection................................................................................................1350 Rear Wiper and Washer Switch Removal and Installation........................................................................................1352 Rear Wiper and Washer Switch Inspection......................................................................................................1352 Rear Wiper Relay Removal and Installation....................................................................................................1352 Rear Wiper Relay Inspection..................................................................................................................1353 Specifications...................................................................................................................................1353 Tightening Torque Specifications.............................................................................................................1353 Glass / Windows / Mirrors............................................................................................................................1354 General Description..............................................................................................................................1354 Rear End Door Window Defogger System Description.............................................................................................1354 Diagnostic Information and Procedures............................................................................................................1354 Rear End door Window / Back Window Defogger Symptom Diagnosis................................................................................1354 Power Window Control System Symptom Diagnosis................................................................................................1354 Power Door Mirror Control System Symptom Diagnosis...........................................................................................1355 Repair Instructions..............................................................................................................................1355 Windshield Components........................................................................................................................1355 Windshield Removal and Installation..........................................................................................................1356 Front Pillar Window Components...............................................................................................................1360 Front Pillar Window Removal and Installation.................................................................................................1360 Rear Quarter Window Components (Hatchback Model).............................................................................................1361 Rear Quarter Window Removal and Installation (Hatchback Model)...............................................................................1361 Rear End Door Window Components (Hatchback Model)............................................................................................1362 Rear End Door Glass Removal and Installation (Hatchback Model)...............................................................................1362 Back Window Components (Sedan Model).........................................................................................................1363 Back Window Removal and Installation (Sedan Model)...........................................................................................1363 Front Door Window Components.................................................................................................................1364 Front Door Glass Removal and Installation....................................................................................................1364 Front Door Window Regulator Removal and Installation.........................................................................................1365 Front Door Window Regulator Inspection.......................................................................................................1366 Rear Door Window Components..................................................................................................................1366 Rear Door Glass Removal and Installation.....................................................................................................1367 Rear Door Window Regulator Removal and Installation..........................................................................................1368 Rear Door Window Regulator Inspection........................................................................................................1369 Rear End Door Window / Back Window Defogger Switch Inspection................................................................................1369 Rear End Door Window / Back Window Defogger Relay Inspection.................................................................................1370 Rear End Door Window / Back Window Defogger Wire Inspection..................................................................................1370 Rear End Door Window / Back Window Defogger Wire Repair......................................................................................1372 Power Window Main Switch Inspection..........................................................................................................1372 Power Window Sub Switch Inspection...........................................................................................................1373 Door Mirror Components.......................................................................................................................1374 Door Mirror Removal and Installation.........................................................................................................1374 Power Door Mirror Switch Inspection..........................................................................................................1374 Power Door Mirror Actuator Inspection........................................................................................................1375 Special Tools and Equipment......................................................................................................................1375 Recommended Service Material.................................................................................................................1375 Security and Locks...................................................................................................................................1376 General Description..............................................................................................................................1376 Key Coding Construction......................................................................................................................1376 Rear End Door Opener System Description......................................................................................................1376 Component Location...............................................................................................................................1377 Power Door Lock and Keyless Entry System Component Location..................................................................................1377 Diagnostic Information and Procedures............................................................................................................1378 Power Door Lock System Symptom Diagnosis.....................................................................................................1378 Power Door Lock System Operation Inspection..................................................................................................1378 Keyless Entry System Symptom Diagnosis.......................................................................................................1379 Keyless Entry System Operation Inspection....................................................................................................1380 Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...................................................................1380 Rear End Door Opener System Symptom Diagnosis................................................................................................1380 Rear End Door Opener System Operation Inspection.............................................................................................1380 Repair Instructions..............................................................................................................................1381 Front Door Lock Assembly Components..........................................................................................................1381 Front Door Lock Assembly Removal and Installation............................................................................................1381 Front Door Lock Assembly Inspection..........................................................................................................1383 Power Door Lock Switch Inspection............................................................................................................1383 Door Key Cylinder Switch Inspection..........................................................................................................1383 Power Door Lock Actuator Inspection..........................................................................................................1384 Rear Door Lock Assembly Components...........................................................................................................1385 Rear Door Lock Assembly Removal and Installation.............................................................................................1385 Rear Door Lock Assembly Inspection...........................................................................................................1385 Rear End Door Lock Assembly Components (Hatchback Model).....................................................................................1386 Rear End Door Lock Assembly Removal and Installation (Hatchback Model).......................................................................1386 Rear End Door Lock Assembly Inspection (Hatchback Model).....................................................................................1387 Rear End Door Opener Switch Inspection (Hatchback Model).....................................................................................1387 Trunk Lid Lock Assembly Components (Sedan Model).............................................................................................1388 Trunk Lid Lock Assembly Removal and Installation (Sedan Model)...............................................................................1389 Trunk Lid Lock Assembly Inspection (Sedan Model).............................................................................................1390 Replacement of Transmitter Battery (Other than Keyless Start Model)..........................................................................1390 Programming Transmitter Code for Keyless Entry System (Other than Keyless Start Model).......................................................1390 Keyless Entry Answer Back Function Change- over Procedure....................................................................................1391 Keyless Entry Receiver Removal and Installation (If Equipped)................................................................................1391 Keyless Entry Receiver and Its Circuit Inspection (If Equipped)..............................................................................1392 Specifications...................................................................................................................................1393 Tightening Torque Specifications.............................................................................................................1393 Special Tools and Equipment......................................................................................................................1393 Recommended Service Material.................................................................................................................1393 Seats................................................................................................................................................1394 Repair Instructions..............................................................................................................................1394 Front Seat Components........................................................................................................................1394 Front Seat Removal and Installation..........................................................................................................1395 Rear Seat Components.........................................................................................................................1395 Rear Seat Removal and Installation...........................................................................................................1397 Specifications...................................................................................................................................1397 Tightening Torque Specifications.............................................................................................................1397 Special Tools and Equipment......................................................................................................................1397 Recommended Service Material.................................................................................................................1397 Interior Trim........................................................................................................................................1398 Repair Instructions..............................................................................................................................1398 Floor Carpet Removal and Installation........................................................................................................1398 Head Lining Removal and Installation.........................................................................................................1399 Console Box Components.......................................................................................................................1401 Specifications...................................................................................................................................1401 Tightening Torque Specifications.............................................................................................................1401 Hood / Fenders / Doors...............................................................................................................................1402 Repair Instructions..............................................................................................................................1402 Hood Removal and Installation................................................................................................................1402 Hood Inspection and Adjustment...............................................................................................................1402 Front Fender Components......................................................................................................................1403 Front Fender Removal and Installation........................................................................................................1403 Front Door Assembly Components...............................................................................................................1404 Front Door Assembly Removal and Installation.................................................................................................1404 Rear Door Assembly Components................................................................................................................1406 Rear Door Assembly Removal and Installation..................................................................................................1406 Rear End Door Assembly Components (Hatchback Model)..........................................................................................1407 Rear End Door Assembly Removal and Installation (Hatchback Model)............................................................................1408 All Latches, Hinges and Locks Inspection.....................................................................................................1409 Trunk Lid Components (Sedan Model)...........................................................................................................1409 Trunk Lid Removal and Installation (Sedan Model).............................................................................................1410 Specifications...................................................................................................................................1412 Tightening Torque Specifications.............................................................................................................1412 Special Tools and Equipment......................................................................................................................1412 Recommended Service Material.................................................................................................................1412 Body Structure.......................................................................................................................................1413 Repair Instructions..............................................................................................................................1413 Front Bumper and Rear Bumper Components......................................................................................................1413 Radiator Grille Removal and Installation.....................................................................................................1414 Front Bumper Extension Removal and Installation (if equipped)................................................................................1415 Rear Bumper Extension Removal and Installation (if equipped).................................................................................1416 Cowl Top and Front Lower Crossmember Components..............................................................................................1417 Specifications...................................................................................................................................1418 Body Dimensions..............................................................................................................................1418 Panel Clearance..............................................................................................................................1430 Tightening Torque Specifications.............................................................................................................1431 Paint / Coatings.....................................................................................................................................1432 General Description..............................................................................................................................1432 Anti-Corrosion Treatment Construction........................................................................................................1432 Plastic Parts Finishing......................................................................................................................1432 Component Location...............................................................................................................................1433 Sealant Application Areas....................................................................................................................1433 Under Coating Application Areas..............................................................................................................1441 Anti-Corrosion Compound Application Area.....................................................................................................1443 Exterior Trim........................................................................................................................................1445 Repair Instructions..............................................................................................................................1445 Roof Molding Removal and Installation........................................................................................................1445 Splash Guard Removal and Installation (If Equipped)..........................................................................................1446 Specifications...................................................................................................................................1446 Tightening Torque Specifications.............................................................................................................1446 Control Systems..........................................................................................................................................1447 Precautions..........................................................................................................................................1449 Precautions......................................................................................................................................1449 Precautions for Control Systems..............................................................................................................1449 Cruise Control System................................................................................................................................1450 General Description..............................................................................................................................1450 Cruise Control System Construction...........................................................................................................1450 Components and Functions of Cruise Control System............................................................................................1451 Cancel Conditions of Cruise Control System...................................................................................................1452 Schematic and Routing Diagram....................................................................................................................1452 Cruise Control System Input / Output Diagram.................................................................................................1452 Cruise Control System Wiring Diagram.........................................................................................................1453 Diagnostic Information and Procedures............................................................................................................1454 Cruise Control System Symptom Diagnosis......................................................................................................1454 Inspection of Cruise Control System Circuit..................................................................................................1455 Repair Instructions..............................................................................................................................1456 Cruise Control Switch Removal and Installation...............................................................................................1456 Cruise Control Switch Inspection.............................................................................................................1456 CPP Switch (for Cruise Control) Removal and Installation.....................................................................................1456 Clutch Pedal Position (CPP) Switch (for Cruise Control) Inspection and Adjustment............................................................1457 Brake Light Switch Removal and Installation..................................................................................................1457 Brake Light Switch Inspection................................................................................................................1457 ECM Removal and Installation.................................................................................................................1457 Specifications...................................................................................................................................1457 Tightening Torque Specifications.............................................................................................................1457 Body Electrical Control System.......................................................................................................................1458 Precautions......................................................................................................................................1458 Precautions in Diagnosing Trouble............................................................................................................1458 General Description..............................................................................................................................1458 BCM General Description......................................................................................................................1458 CAN Communication System Description.........................................................................................................1458 Theft Deterrent Light Description............................................................................................................1459 Schematic and Routing Diagram....................................................................................................................1459 Body Electrical Control System Wiring Circuit Diagram........................................................................................1459 Connector Layout Diagram of BCM and Junction Block...........................................................................................1462 Component Location...............................................................................................................................1463 BCM and Related System Component Location....................................................................................................1463 Diagnostic Information and Procedures............................................................................................................1464 BCM Self-Diagnosis Function..................................................................................................................1464 Body Electrical Control System Check.........................................................................................................1465 Scan Tool Data...............................................................................................................................1467 DTC Table....................................................................................................................................1469 DTC Check....................................................................................................................................1469 DTC Clearance................................................................................................................................1470 BCM Power Circuit and Ground Circuit Check...................................................................................................1471 DTC B1133 (No. 1133): Battery Voltage Too High...............................................................................................1472 DTC B1141 / B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction..................................1473 DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction..............................................................................1474 DTC B1157 (No. 1157): Air Bag Deployment Signal Input........................................................................................1475 DTC B1170 (No. 1170): EEPROM Access Error....................................................................................................1475 DTC U0073 (No. 0073): Control Module Communication Bus Off...................................................................................1475 DTC U0100 (No. 0100): Lost Communication with ECM............................................................................................1475 DTC U0101 (No. 0101): Lost Communication with TCM............................................................................................1475 DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module..................................................1475 DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...................................................................1475 Inspection of BCM and Its Circuits...........................................................................................................1476 Repair Instructions..............................................................................................................................1483 BCM (Included in Junction Block) Removal and Installation....................................................................................1483 Outside Air Temperature Sensor Removal and Installation......................................................................................1484 Outside Air Temperature Sensor Inspection....................................................................................................1484 Special Tools and Equipment......................................................................................................................1484 Special Tool.................................................................................................................................1484 Immobilizer Control System...........................................................................................................................1485 Precautions......................................................................................................................................1485 Precautions in Diagnosing Troubles...........................................................................................................1485 Precaution in Replacing ECM..................................................................................................................1485 Precaution in Replacing Ignition Key.........................................................................................................1485 Precautions in Handling Immobilizer Control System...........................................................................................1485 General Description..............................................................................................................................1486 Immobilizer Control System Introduction......................................................................................................1486 On-Board Diagnostic System Description (Self-diagnosis Function).............................................................................1486 Schematic and Routing Diagram....................................................................................................................1487 Immobilizer Control System Wiring Circuit Diagram............................................................................................1487 Component Location...............................................................................................................................1488 Immobilizer Control System Components Location...............................................................................................1488 Diagnostic Information and Procedures............................................................................................................1488 Immobilizer Control System Check.............................................................................................................1488 DTC Check....................................................................................................................................1489 DTC Clearance................................................................................................................................1489 DTC Table....................................................................................................................................1490 Scan Tool Data...............................................................................................................................1491 Immobilizer Indicator Light Does Not Come ON with Ignition Switch ON and Engine Stop.........................................................1492 Immobilizer Indicator Light Remains ON after Engine Start....................................................................................1493 DTC P1614: Transponder Response Error........................................................................................................1493 DTC P1615: Steering Lock Unit Communication Error............................................................................................1494 DTC P1616: Unregistered Keyless Start Control Module.........................................................................................1495 DTC P1618: Keyless Start Control Module CAN Communication Error..............................................................................1495 DTC P1621: Immobilizer Communication Line Error..............................................................................................1496 DTC P1622: EEPROM Reading / Writing Error....................................................................................................1497 DTC P1623: Unregistered Transponder..........................................................................................................1497 DTC P1625: Immobilizer Antenna Error.........................................................................................................1497 DTC P1636: Immobilizer Information Registration Failure......................................................................................1498 DTC P1638: Immobilizer Information Mismatched................................................................................................1499 Inspection of ICM and Its Circuit............................................................................................................1500 Repair Instructions..............................................................................................................................1502 ICM Removal and Installation.................................................................................................................1502 Registration of the Ignition Key.............................................................................................................1502 Procedure after ECM Replacement..............................................................................................................1502 Special Tools and Equipment......................................................................................................................1503 Special Tool.................................................................................................................................1503 Keyless Start System.................................................................................................................................1504 Precautions......................................................................................................................................1504 Precautions in Diagnosing Troubles...........................................................................................................1504 General Description..............................................................................................................................1505 Keyless Start System Description.............................................................................................................1505 Parts and Functions..........................................................................................................................1506 Keyless Engine Start Function................................................................................................................1507 Door Lock Function of Keyless Start System...................................................................................................1508 Trunk Lid Opener Function of Keyless Start System (Sedan)....................................................................................1509 Operation Area of Remote Controller..........................................................................................................1510 Alarm Function...............................................................................................................................1511 CAN Communication System Description.........................................................................................................1511 Schematic and Routing Diagram....................................................................................................................1512 Keyless Start System Electric Wiring Circuit Diagram.........................................................................................1512 Diagnostic Information and Procedures............................................................................................................1513 Self-Diagnosis Function......................................................................................................................1513 Keyless Start System Diagnosis Introduction..................................................................................................1513 Keyless Start System Check...................................................................................................................1513 Customer Questionnaire (Example).............................................................................................................1514 Key Indicator Light Check....................................................................................................................1514 DTC Check....................................................................................................................................1515 DTC Table....................................................................................................................................1516 DTC Clearance................................................................................................................................1516 Keyless Start System Symptom Diagnosis.......................................................................................................1517 Keyless Start System Operation Inspection....................................................................................................1519 Door Lock Operation Check (Keyless Start System).............................................................................................1519 Inspection of Keyless Start Control Module and Its Circuits..................................................................................1520 No DTC Detection After Performing DTC Check..................................................................................................1525 Key Indicator Light Circuit Check (Key Indicator Light Doesn’t Light when Ignition Knob Switch is Pushed)....................................1526 Keyless Start Control Module Power and Ground Circuit Check..................................................................................1528 DTC No. 11: Communication Error with Steering Lock Unit......................................................................................1529 DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...........................................1530 DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM Reading Error) / (EEPROM Writing Error)..........................1530 DTC No. 31: Lost Communication with BCM......................................................................................................1531 DTC No. 33: Control Module Communication Bus Off.............................................................................................1531 DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door / Trunk Lid Request Switch Failure................................1531 Repair Instructions..............................................................................................................................1532 Antennas and Request Switches Removal and Installation.......................................................................................1532 Front Door (Driver and Passenger Side), Rear End Door / Trunk Lid Request Switch Inspection..................................................1533 Steering Lock Unit Removal and Installation..................................................................................................1533 Steering Lock Unit Inspection................................................................................................................1533 Front Door Lock Switch Inspection............................................................................................................1534 Keyless Start Control Module Removal and Installation........................................................................................1534 Remote Controller Inspection.................................................................................................................1534 Replacement of Remote Controller Battery.....................................................................................................1534 Registration Procedure for Remote Controller ID Code.........................................................................................1535 Keyless Start Registration...................................................................................................................1536 COPYRIGHT................................................................................................................................................1537 BOOKCOVER_VOL1...........................................................................................................................................1538 BOOKCOVER_VOL2...........................................................................................................................................1539
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