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Suzuki Wagon R+ RB310 RB413 RB413D Supplementary Service Manual – PDF DOWNLOAD
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Suzuki Wagon R+ RB310 RB413 RB413D Supplementary Service Manual – PDF DOWNLOAD
FILE DETAILS:
Suzuki Wagon R+ RB310 RB413 RB413D Supplementary Service Manual – PDF DOWNLOAD
Language : English
Pages : 912
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Suzuki Wagon R+ RB310 RB413 RB413D Supplementary Service Manual – PDF DOWNLOAD
Top............................................................................................................. 0 Manual List..................................................................................................... 0 IMPORTANT....................................................................................................... 1 WARNING/CAUTION/NOTE........................................................................................ 1 Foreword........................................................................................................ 2 Table of Contents............................................................................................... 4 SECTION 0A...................................................................................................... 6 How to Use This Manual...................................................................................... 7 Precautions................................................................................................. 8 Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System......................... 8 Diagnosis........................................................................................... 9 Servicing and handling.............................................................................. 10 General Precautions..................................................................................... 12 Precaution for CAN Communication System................................................................. 15 Precaution for Wheel (with Tire) Removal................................................................ 15 Precautions for Catalytic Converter..................................................................... 15 Precaution for Installing Mobile Communication Equipment................................................ 16 Precaution in Servicing Full-Time 4WD Vehicle........................................................... 16 Precautions for Electrical Circuit Service.............................................................. 17 Electrical Circuit Inspection Procedure................................................................. 20 Open circuit check.................................................................................. 20 Continuity check.................................................................................... 21 Voltage check....................................................................................... 21 Short circuit check (wire harness to ground)........................................................ 22 Intermittent and Poor Connection........................................................................ 22 Identification Information.................................................................................. 24 Vehicle Identification Number........................................................................... 24 Engine Identification Number............................................................................ 24 Transmission Identification Number...................................................................... 24 Warning, Caution and Information Labels..................................................................... 25 Vehicle Lifting Points...................................................................................... 26 When using frame contact hoist.......................................................................... 26 When using floor jack................................................................................... 27 Abbreviations and Symbols May be Used in This Manual........................................................ 28 Abbreviations........................................................................................... 28 Symbols................................................................................................. 30 Wire Color Symbols...................................................................................... 30 Fastener Information........................................................................................ 31 Metric Fasteners Information............................................................................ 31 Fastener Strength Identification........................................................................ 32 Standard Tightening Torque.............................................................................. 32 SECTION 0B...................................................................................................... 34 Maintenance Schedule........................................................................................ 36 Maintenance Schedule Under Normal Driving Conditions.................................................... 36 Maintenance Recommended Under Severe Driving Conditions................................................. 39 Maintenance Service......................................................................................... 41 Drive Belt Inspection (M13 Engine)...................................................................... 41 Water pump and generator drive belt inspection...................................................... 41 A/C Compressor drive belt (if equipped) inspection.................................................. 41 Drive Belt Replacement (M13 Engine)..................................................................... 41 Water pump and generator drive belt replacement..................................................... 41 A/C Compressor drive belt (if equipped) replacement................................................. 41 Drive Belt Inspection (G10 Engine)...................................................................... 42 A/C compressor drive belt inspection (If equipped).................................................. 42 Water pump belt inspection.......................................................................... 42 Drive Belt Replacement (G10 Engine)..................................................................... 42 A/C compressor drive belt replacement............................................................... 42 Water pump belt replacement......................................................................... 42 Engine Accessary Drive Belt Inspection (Z13DT Engine)................................................... 43 Water pump and generator drive belt inspection...................................................... 43 Engine Accessary Drive Belt Replacement (Z13DT Engine).................................................. 43 Water pump and generator drive belt replacement..................................................... 43 Camshaft Timing Belt Replacement (G10 Engine)........................................................... 43 Valve Lash (Clearance) Inspection (M13 Engine).......................................................... 43 Engine Oil and Oil Filter Replacement (G10/ M13 Engines)................................................ 44 Engine Oil and Oil Filter Replacement (Z13DT Engine).................................................... 46 Engine Coolant Replacement.............................................................................. 48 Exhaust System Inspection............................................................................... 48 Spark Plugs Replacement................................................................................. 48 Distributor Cap and Rotor Inspection (G10 Engine)....................................................... 49 Air Cleaner Filter Inspection (G10/M13 Engines)......................................................... 49 Air Cleaner Filter Replacement (G10/M13 Engines)........................................................ 49 Air Cleaner Filter Inspection (Z13DT Engine)............................................................ 49 Air Cleaner Filter Replacement (Z13DT Engine)........................................................... 50 Fuel Lines and Connections Inspection................................................................... 50 Fuel Filter Replacement (Z13DT Engine).................................................................. 50 Water Draining of Fuel Filter (Z13DT Engine)............................................................ 50 Fuel Tank Inspection.................................................................................... 51 PCV Valve Inspection.................................................................................... 51 Fuel Evaporative Emission Control System Inspection..................................................... 51 Brake Discs and Pads (Front) Inspection................................................................. 51 Brake Drums and Shoes (Rear) Inspection................................................................. 52 Brake Hoses and Pipes Inspection........................................................................ 52 Brake Fluid Replacement................................................................................. 52 Brake Lever and Cable Inspection........................................................................ 52 Clutch Inspection....................................................................................... 53 Tires Inspection........................................................................................ 53 Wheel Discs Inspection.................................................................................. 54 Wheel Bearing Inspection................................................................................ 54 Suspension System Inspection............................................................................ 54 Steering System Inspection.............................................................................. 55 Drive Shaft (Axle) Boots Inspection..................................................................... 56 Propeller Shafts (4WD) Inspection....................................................................... 56 Manual Transmission Oil Inspection (G10/M13 Engines).................................................... 56 Manual Transmission Oil Replacement..................................................................... 56 Automatic Transmission Fluid Level Inspection........................................................... 57 Automatic Transmission Fluid Replacement................................................................ 57 Automatic Transmission Fluid Cooler Hose Inspection..................................................... 57 Transfer Oil (4WD) and Rear Differential Oil (4WD) Inspection........................................... 58 Transfer Oil (4WD) and Rear Differential Oil (4WD) Replacement.......................................... 58 All Latches, Hinges and Locks Inspection................................................................ 59 Doors............................................................................................... 59 Engine hood......................................................................................... 59 Ventilator Air Filter (If Equipped)..................................................................... 59 Final Inspection............................................................................................ 60 Recommended Fluids and Lubricants........................................................................... 62 SECTION 1A...................................................................................................... 64 General Description......................................................................................... 65 Major Components and Location........................................................................... 65 On-Board Diagnostic System (Z13DT Engine Model)......................................................... 67 Diagnosis................................................................................................... 68 Diagnosis Table......................................................................................... 68 Wiring Circuit.......................................................................................... 69 Diagnostic Trouble Code (DTC) Check (Z13DT Engine Model)................................................ 70 Diagnostic Trouble Code (DTC) Table (Z13DT Engine Model)................................................ 71 On-Vehicle Service.......................................................................................... 73 Heater Unit............................................................................................. 73 Supplementary Heater (if equipped) (Z13DT Engine)....................................................... 75 Supplementary Heater Controller (if equipped) (Z13DT Engine)............................................ 75 Supplementary Heater Relay (if equipped) (Z13DT Engine)................................................. 75 Air Inlet Box........................................................................................... 76 SECTION 1B...................................................................................................... 78 General Description......................................................................................... 79 Major Components and Location........................................................................... 79 Diagnosis................................................................................................... 81 General Diagnosis Table................................................................................. 81 Wiring Circuit.......................................................................................... 83 A/C System Inspection of ECM and Its circuits (M13 Engine Model)........................................ 86 Compressor Drive Belt................................................................................... 89 Recovery, Evacuation and Charging........................................................................... 90 Operation Procedure for Charging A/C with Refrigerant................................................... 90 On-Vehicle Service.......................................................................................... 91 Procedure After ECM Replacement (Z13DT Engine Model).................................................... 92 A/C Condenser Assembly.................................................................................. 92 Receiver / Dryer........................................................................................ 94 Cooling Unit (Evaporator)............................................................................... 95 Dual Pressure Switch (M13 and G10 Engine Models)........................................................ 96 Pressure Sensor (Z13DT Engine Model).................................................................... 97 A/C Relay (Z13DT Engine)................................................................................ 98 A/C Compressor Relay.................................................................................... 99 Compressor.............................................................................................. 99 Replenishing Compressor Oil.........................................................................101 Magnet Clutch...........................................................................................102 Relief Valve (Z13DT Engine Model).......................................................................103 Required Service Material...................................................................................103 SECTION 3A......................................................................................................104 General Description.........................................................................................105 Front Wheel Alignment Specifications....................................................................105 SECTION 3B......................................................................................................106 On-Vehicle Service..........................................................................................107 Tie Rod End.............................................................................................107 Manual Rack and Pinion Assembly (Steering Gear Case)....................................................108 Tightening Torque Specifications............................................................................109 SECTION 3B1.....................................................................................................110 General Description.........................................................................................111 Wiring Diagram..........................................................................................111 Diagnosis...................................................................................................112 “EPS” Warning Lamp Circuit Check Flow Table for M13 Engine Model........................................112 Table-B “EPS” Warning Lamp Remains ON...................................................................113 SECTION 3D......................................................................................................114 General Description.........................................................................................115 Diagnosis...................................................................................................116 Wheel Disc, Bolt & Bearing Check........................................................................116 On-Vehicle Service..........................................................................................117 Stabilizer Bar and/or Bushings..........................................................................117 Strut Assembly..........................................................................................118 Steering Knuckle / Bearing..............................................................................119 Suspension Control Arm / Bushing........................................................................125 Tightening Torque Specifications............................................................................127 Required Service Material...................................................................................128 Special Tool................................................................................................128 SECTION 3E......................................................................................................130 General Description.........................................................................................131 Diagnosis...................................................................................................133 Wheel Disc, Bolt and Bearing Check......................................................................133 On-Vehicle Service..........................................................................................134 Lateral Rod.............................................................................................136 Coil Spring.............................................................................................137 Bump Stopper............................................................................................138 Trailing Arm............................................................................................138 Rear Axle (for 2WD Model)...............................................................................140 Wheel Bearing (for 2WD Model)...........................................................................142 Rear Axle Shaft and Wheel Bearing (for 4WD Model).......................................................144 Rear Axle Housing (for 4WD Model).......................................................................148 Tightening Torque Specifications............................................................................153 Required Service Material...................................................................................154 Special Tool................................................................................................155 SECTION 3F......................................................................................................156 General Description.........................................................................................157 Tires...................................................................................................157 Maintenance And Minor Adjustments...........................................................................157 Wheel Maintenance.......................................................................................157 Tire Rotation...........................................................................................157 On-Vehicle Service..........................................................................................158 Service Operations......................................................................................158 Wheel Bolts.........................................................................................158 Wheel...............................................................................................158 Tightening Torque Specifications............................................................................159 SECTION 4A......................................................................................................160 General Description.........................................................................................160 Diagnosis...................................................................................................160 On-Vehicle Service..........................................................................................161 Front Drive Shaft Assembly Construction.................................................................161 Front Drive Shaft Assembly Removal and Installation.....................................................162 Front Drive Shaft Assembly Inspection...................................................................164 Front Drive Shaft Components............................................................................165 Front Drive Shaft Disassembly and Assembly..............................................................166 Front Drive Shaft Inspection............................................................................175 Center Shaft and Center Bearing Support Disassembly and Assembly (2WD Model with M13 Engine)............176 Tightening Torque Specification.............................................................................177 RequirPed Service Material..................................................................................178 Special Tools...............................................................................................178 SECTION 4A3.....................................................................................................180 General Description.........................................................................................180 Diagnosis...................................................................................................180 On-Vehicle Service..........................................................................................181 Front Drive Shaft Assembly Construction.................................................................181 Front Drive Shaft Assembly Removal and Installation.....................................................182 Front Drive Shaft Assembly Inspection...................................................................183 Front Drive Shaft Components............................................................................184 Front Drive Shaft Disassembly and Assembly..............................................................185 Front Drive Shaft Inspection............................................................................191 Tightening Torque Specification.............................................................................191 Special Tools...............................................................................................191 SECTION 4B......................................................................................................192 On-Vehicle Service..........................................................................................193 Tightening Torque Specification.............................................................................197 SECTION 5.......................................................................................................198 General Description.........................................................................................199 Check and Adjustment........................................................................................200 Bleeding Brakes.........................................................................................200 Brake Shoe Check........................................................................................202 Tightening Torque Specifications............................................................................202 SECTION 5A......................................................................................................204 On-Vehicle Service..........................................................................................205 Rear Brake Hose/Pipe....................................................................................205 SECTION 5B......................................................................................................208 On-Vehicle Service..........................................................................................209 Front Disc Brake Pad....................................................................................209 Front Disc Brake Caliper................................................................................210 Front Brake Disc........................................................................................211 Tightening Torque Specification.............................................................................212 SECTION 5C......................................................................................................214 On-Vehicle Service..........................................................................................215 Parking Brake Cable Component Location..................................................................217 Brake Drum (for 2WD Model)..............................................................................218 Brake Drum Removal and Installation (for 4WD Model).....................................................220 Brake Back Plate (for 2WD Model)........................................................................222 Brake Back Plate (for 4WD Model)........................................................................224 Tightening Torque Specifications............................................................................224 Required Service Material...................................................................................224 Special Tools...............................................................................................225 SECTION 6-2.....................................................................................................226 General Information.........................................................................................228 Statement on Cleanliness and Care.......................................................................228 Precaution..............................................................................................229 Precaution on engine service........................................................................229 Precaution on fuel system service...................................................................229 Fuel pressure relief procedure......................................................................230 Fuel leakage check procedure........................................................................231 Diagnosis...................................................................................................232 Engine Diagnosis General Description....................................................................232 On-Board Diagnostic System Description..................................................................232 Precaution in Diagnosing Trouble for Engine.............................................................235 Engine and Emission Control System Check................................................................236 Customer Problem Inspection Form (Example)..............................................................238 Malfunction Indicator Lamp (MIL) Check..................................................................239 Diagnostic Trouble Code (DTC) Check.....................................................................239 Diagnostic Trouble Code (DTC) Clearance.................................................................239 DTC Table...............................................................................................241 Fail-Safe Table.........................................................................................244 Visual Inspection.......................................................................................245 Engine Basic Inspection.................................................................................246 Engine Symptom Diagnosis................................................................................248 Scan Tool Data..........................................................................................256 Inspection of ECM and Its Circuits......................................................................261 Table A-1 Malfunction Indicator Lamp Circuit Check – Lamp Does Not Come “ON” with Ignition Switch.......279 Table A-2 Malfunction Indicator Lamp Circuit Check-lamp Remains “ON” after Engine Starts................281 Table A-3 ECM Power and Ground Circuit Check-MIL Doesn’t Light with Ignition Switch ON and Engine.......283 DTC P0010 Camshaft Position Actuator Circuit............................................................286 DTC P0011 Camshaft Position – Timing Over-Advanced or System Performance................................289 DTC P0012 Camshaft Position – Timing Over-Retarded......................................................289 DTC P0102 Mass Air Flow Circuit Low Input...............................................................291 DTC P0103 Mass Air Flow Circuit High Input..............................................................294 DTC P0112 Intake Air Temperature Sensor Circuit Low.....................................................296 DTC P0113 Intake Air Temperature Sensor Circuit High....................................................298 DTC P0117 Engine Coolant Temperature Circuit Low........................................................301 DTC P0118 Engine Coolant Temperature Circuit High.......................................................303 DTC P0121 Throttle Position Sensor Circuit Range/Performance............................................306 DTC P0122 Throttle Position Sensor Circuit Low..........................................................310 DTC P0123 Throttle Position Circuit High Input..........................................................313 DTC P0131 O2 Sensor (HO2S) Circuit Low Voltage (Sensor-1)...............................................316 DTC P0132 O2 Sensor (HO2S) Circuit High Voltage (Sensor-1)..............................................316 DTC P0133 O2 Sensor (HO2S) Circuit Slow Response (Sensor-1).............................................319 DTC P0134 O2 Sensor (HO2S) No Activity Detected (Sensor-1)..............................................320 DTC P0031 HO2S Heater Control Circuit Low (Sensor-1)....................................................323 DTC P0032 HO2S Heater Control Circuit High (Sensor-1)...................................................323 DTC P0136 O2 Sensor (HO2S) Circuit (Sensor-2)...........................................................326 DTC P0037 HO2S Heater Control Circuit Low (Sensor-2)....................................................329 DTC P0038 HO2S Heater Control Circuit High (Sensor-2)...................................................329 DTC P0171 System Too Lean...............................................................................331 DTC P0172 System Too Rich...............................................................................331 DTC P0300 Random Misfire Detected.......................................................................333 DTC P0301 Cylinder 1 Misfire Detected...................................................................333 DTC P0302 Cylinder 2 Misfire Detected...................................................................333 DTC P0303 Cylinder 3 Misfire Detected...................................................................333 DTC P0304 Cylinder 4 Misfire Detected...................................................................333 DTC P0327 Knock Sensor Circuit Low......................................................................335 DTC P0328 Knock Sensor Circuit High.....................................................................335 DTC P0335 Crankshaft Position (CKP) Sensor Circuit......................................................337 DTC P0340 Camshaft Position Sensor Circuit..............................................................341 DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected..........................................345 DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected.............................................345 DTC P0420 Catalyst System Efficiency Below Threshold....................................................348 DTC P0443 Evaporative Emission System Purge Control Valve Circuit.......................................350 DTC P0480 Fan 1 (Radiator Cooling Fan) Control Circuit..................................................352 DTC P0500 Vehicle Speed Sensor (VSS) Malfunction........................................................355 DTC P0505 Idle Air Control System.......................................................................359 DTC P1500 Starter Signal Circuit Malfunction............................................................361 DTC P0107 Manifold Absolute Pressure Low Input..........................................................363 DTC P0108 Manifold Absolute Pressure High Input.........................................................366 DTC P0601 Internal Control Module Memory Check Sum Error................................................368 DTC P0602 Control Module Programming Error..............................................................368 DTC P1510 ECM Back-up Power Supply Malfunction..........................................................369 DTC P1601 Can Communication Error.......................................................................371 DTC P1603 TCM Trouble Code Detected.....................................................................373 DTC P2227 Barometric Pressure Circuit Range/Performance.................................................374 DTC P2228 Barometric Pressure Circuit Low...............................................................374 DTC P2229 Barometric Pressure Circuit High..............................................................374 Table B-1 Fuel Injector Circuit Check...................................................................375 Table B-2 Fuel Pump and Its Circuit Check...............................................................377 Table B-3 Fuel Pressure Check...........................................................................379 Table B-4 Idle Air Control System Check.................................................................381 Table B-5 A/C Signal Circuits Check (Vehicle with A/C)..................................................383 Table B-6 Electric Load Signal Circuit Check............................................................386 Table B-7 Radiator Fan Control System Check.............................................................387 Special Tool................................................................................................389 SECTION 6A2.....................................................................................................390 General Description.........................................................................................392 Engine Construction Description.........................................................................392 Engine Lubrication Description..........................................................................393 Variable Valve Timing (VVT) System Description..........................................................394 System description..................................................................................394 Oil control valve...................................................................................395 Cam timing sprocket.................................................................................395 Timing advancing....................................................................................395 Timing holding......................................................................................395 Timing retarding....................................................................................396 Targeted timing varying operation...................................................................396 Diagnosis...................................................................................................397 Diagnosis Table.........................................................................................397 Compression Check.......................................................................................397 Engine Vacuum Check.....................................................................................398 Oil Pressure Check......................................................................................400 Valve Lash (Clearance) Inspection.......................................................................402 Shim Replacement........................................................................................402 On-Vehicle Service..........................................................................................405 Air Cleaner Element Removal and Installation............................................................405 Air Cleaner Element Inspection and Cleaning.............................................................406 Knock Sensor Removal and Installation...................................................................406 Cylinder Head Cover Removal and Installation............................................................406 Throttle Body and Intake Manifold Components............................................................409 Throttle Body Removal and Installation..................................................................410 Intake Manifold Removal and Installation................................................................411 Exhaust Manifold Components.............................................................................412 Exhaust Manifold Removal and Installation...............................................................413 Oil Pan and Oil Pump Strainer Components................................................................415 Oil Pan and Oil Pump Strainer Removal and Installation..................................................415 Engine Mountings Components.............................................................................418 Unit Repair Overhaul........................................................................................419 Engine Assembly Removal and Installation................................................................419 Timing Chain Cover Components...........................................................................423 Timing Chain Cover Removal and Installation.............................................................424 Timing Chain Cover Inspection...........................................................................427 Oil seal............................................................................................427 Timing chain cover..................................................................................427 Oil control valve...................................................................................428 Oil gallery pipe....................................................................................428 Oil Pump Components.....................................................................................428 Oil Pump Removal and Installation.......................................................................429 Oil Pump Disassembly and Assembly.......................................................................429 Oil Pump Inspection.....................................................................................431 Oil seal............................................................................................431 Oil pump assembly...................................................................................431 Radial clearance....................................................................................432 Side clearance......................................................................................432 Relief valve spring free length and load............................................................432 Timing Chain and Chain Tensioner Components.............................................................433 Timing Chain and Chain Tensioner Removal and Installation...............................................433 Timing Chain and Timing Chain Tensioner Inspection......................................................437 Timing chain tensioner..............................................................................437 Crankshaft timing sprocket..........................................................................437 Timing chain........................................................................................438 Timing chain tensioner adjuster.....................................................................438 Timing chain No.1 guide.............................................................................438 Camshaft, Tappet and Shim Components....................................................................439 Camshaft, Tappet and Shim Removal and Installation......................................................439 Camshaft, Tappet and Shim Inspection....................................................................442 Intake cam timing sprocket assembly.................................................................442 Cam wear............................................................................................443 Camshaft runout.....................................................................................443 Camshaft journal wear...............................................................................443 Wear of tappet and shim.............................................................................444 Valves and Cylinder Head Components.....................................................................445 Valves and Cylinder Head Removal and Installation.......................................................446 Valves and Cylinder Head Disassembly and Assembly.......................................................449 Valves and Cylinder Head Inspection.....................................................................452 Valve guides........................................................................................452 Valves..............................................................................................452 Cylinder head.......................................................................................454 Valve springs.......................................................................................455 Pistons, Piston Rings, Connecting Rods and Cylinders Components.........................................456 Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation...........................457 Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly...........................458 Pistons, Piston Rings, Connecting Rods and Cylinders Inspection.........................................460 Cylinder............................................................................................460 Pistons.............................................................................................460 Piston pin..........................................................................................461 Piston rings........................................................................................462 Connecting rod......................................................................................463 Crank pin and connecting rod bearings...............................................................464 Main Bearings, Crankshaft and Cylinder Block Components.................................................468 Main Bearings, Crankshaft and Cylinder Block Removal and Installation...................................469 Main Bearings, Crankshaft and Cylinder Block Inspection.................................................473 Main bearing cap No.1 bolt..........................................................................473 Crankshaft..........................................................................................473 Main bearings.......................................................................................474 Rear oil seal.......................................................................................479 Flywheel............................................................................................479 Sensor plate........................................................................................480 Cylinder block......................................................................................480 Required Service Material...................................................................................481 Tightening Torque Specification.............................................................................481 Special Tool................................................................................................483 SECTION 6B2.....................................................................................................486 General Description.........................................................................................487 Cooling System Circulation..............................................................................487 Coolant.................................................................................................488 Diagnosis...................................................................................................489 Diagnosis Table.........................................................................................489 System Circuit Inspection...............................................................................489 Maintenance.................................................................................................490 Coolant Level Check.....................................................................................490 Engine Cooling System Inspection and Service............................................................491 Cooling System Flush and Refill.........................................................................491 Water Pump/Generator Drive Belt Tension Inspection and Adjustment.......................................493 On-Vehicle Service..........................................................................................494 Cooling System Components...............................................................................494 Cooling System Draining.................................................................................495 Cooling System Refill...................................................................................495 Cooling Water Pipes or Hoses............................................................................495 Thermostat Removal and Installation.....................................................................496 Thermostat Inspection...................................................................................496 Radiator Removal and Installation.......................................................................497 Radiator Inspection.....................................................................................498 Radiator Cleaning.......................................................................................498 Radiator Cooling Fan Relay Inspection...................................................................498 Radiator Cooling Fan Removal and Installation...........................................................498 Radiator Cooling Fan Inspection.........................................................................499 Water Pump/Generator Drive Belt Removal and Installation................................................500 Water Pump Removal and Installation.....................................................................501 Water Pump Inspection...................................................................................502 Engine Coolant Temperature Sensor (ECT Sensor) Removal and Installation.................................502 Engine Coolant Temperature Sensor (ECT Sensor) Inspection...............................................502 Required Service Material...................................................................................502 Tightening Torque Specification.............................................................................503 SECTION 6E2.....................................................................................................504 General Description.........................................................................................506 Engine and Emission Control System Construction.........................................................506 Air Intake System Description...........................................................................509 Fuel Delivery System Description........................................................................510 Electronic Control System Description...................................................................511 On-Vehicle Service..........................................................................................518 Accelerator cable adjustment............................................................................518 Idle speed/idle air control (IAC) duty inspection.......................................................518 Air Intake System.......................................................................................520 Throttle body Components............................................................................520 Throttle body on-vehicle inspection.................................................................520 Throttle body removal and installation..............................................................520 Throttle body cleaning..............................................................................522 Idle air control (IAC) valve operation check........................................................522 Idle air control (IAC) valve removal and installation...............................................522 Idle air control (IAC) valve check..................................................................523 Oil control valve removal and installation..........................................................524 Oil control valve inspection........................................................................524 Fuel Delivery System....................................................................................525 Fuel pressure inspection............................................................................525 Fuel pump with pressure regulator on-vehicle inspection.............................................526 Fuel pump with pressure regulator removal and installation..........................................527 Fuel pump with pressure regulator inspection........................................................527 Fuel injector on-vehicle inspection.................................................................527 Fuel injector removal and installation..............................................................528 Fuel injector inspection............................................................................529 Electronic Control System...............................................................................531 Engine control module (ECM) removal and installation................................................531 Manifold absolute pressure sensor (MAP sensor) inspection...........................................532 Throttle position sensor (TP sensor) on-vehicle inspection..........................................533 Throttle position sensor (TP sensor) removal and installation.......................................533 Engine coolant temperature sensor (ECT sensor) removal and installation.............................534 Engine coolant temperature sensor (ECT sensor) inspection...........................................535 Heated oxygen sensor (HO2S-1 and HO2S-2) heater on-vehicle inspection...............................535 Heated oxygen sensor (HO2S-1 and HO2S-2) removal and installation...................................536 Camshaft position sensor (CMP sensor) and its circuit inspection....................................536 Camshaft position sensor (CMP sensor) removal and installation......................................537 Crankshaft position sensor (CKP sensor) and its circuit inspection..................................537 Crankshaft position sensor (CKP sensor) removal and installation....................................538 Fuel Level Sensor Removal and Installation..........................................................538 Fuel Level Sensor Inspection........................................................................538 Vehicle speed sensor (VSS) and its circuit inspection...............................................539 Vehicle speed sensor (VSS) removal and installation.................................................539 Knock sensor removal and installation...............................................................539 Main relay, fuel pump relay and radiator fan relay inspection.......................................540 Fuel cut operation inspection.......................................................................540 Radiator fan control system inspection..............................................................541 Mass air flow (MAF) and intake air temperature (IAT) sensor on-vehicle inspection...................541 Mass air flow (MAF) and intake air temperature (IAT) sensor removal and installation................542 Mass air flow (MAF) and intake air temperature (IAT) sensor inspection..............................543 Emission Control System.................................................................................544 EGR system inspection...............................................................................544 EGR valve removal and installation..................................................................544 EGR valve inspection................................................................................544 Evaporative emission control system inspection......................................................545 PCV system inspection...............................................................................548 Special Tool................................................................................................550 Tightening Torque Specification.............................................................................551 SECTION 6F2.....................................................................................................552 General Description.........................................................................................553 Ignition System Construction............................................................................553 Ignition System Components Locator Diagram..............................................................553 Ignition System Wiring Circuit Diagram..................................................................554 Diagnosis...................................................................................................555 Ignition System Symptom Diagnosis.......................................................................555 Reference Waveform......................................................................................556 Ignition System Diagnostic Flow Table...................................................................556 On-Vehicle Service..........................................................................................558 Ignition Spark Test.....................................................................................558 High-Tension Cords Removal and Installation.............................................................558 High-Tension Cords Inspection...........................................................................559 Spark Plugs Removal and Installation....................................................................559 Spark Plugs Inspection..................................................................................560 Ignition Coil Assembly (Including Ignitor) Removal and Installation.....................................561 Ignition Coil Assembly (Including Ignitor) Inspection...................................................561 Crankshaft Position (CKP) Sensor........................................................................562 Ignition Timing Inspection..............................................................................562 Tightening Torque Specification.............................................................................563 Special Tool................................................................................................563 SECTION 6G......................................................................................................564 Specifications..............................................................................................565 SECTION 6H......................................................................................................566 Generator...................................................................................................567 Diagnosis...............................................................................................567 Undercharged battery................................................................................567 Unit Repair Overhaul....................................................................................568 Removal and installation............................................................................568 Specifications..............................................................................................568 Generator...............................................................................................568 SECTION 6K2.....................................................................................................570 General Description.........................................................................................571 Maintenance.................................................................................................571 On-Vehicle Service..........................................................................................572 Exhaust System Components...............................................................................572 Exhaust Manifold Removal and Installation...............................................................573 Exhaust Manifold Inspection.............................................................................573 Exhaust Pipe Removal and Installation...................................................................573 Tightening Torque Specification.............................................................................573 SECTION 7A2.....................................................................................................574 General Description.........................................................................................575 Manual Transaxle Construction and Servicing.............................................................575 Transaxle for 2wd Model.................................................................................576 Transaxle for 4wd Model.................................................................................577 Diagnosis...................................................................................................578 Manual Transaxle Symptom Diagnosis......................................................................578 On-Vehicle Service..........................................................................................579 Manual Transaxle Oil Change.............................................................................579 Differential Side Oil Seal Replacement..................................................................579 Gear Shift Control Lever and Cable Components...........................................................581 Gear Shift Control Lever and Cable Removal and Installation.............................................582 Gear Shift Control Lever and Cable Adjustment...........................................................583 Vehicle Speed Sensor (VSS) Removal and Installation.....................................................584 Back Up Lamp Switch Removal and Installation............................................................585 Back Up Lamp Switch Inspection..........................................................................585 Unit Repair Overhaul........................................................................................586 Transaxle Unit Components...............................................................................586 Transaxle Unit Dismounting and Remounting...............................................................587 Transaxle Case Components...............................................................................589 Gear Shift and Select Shaft Assembly Components.........................................................590 Gear Shift and Select Shaft Assembly Removal and Installation...........................................591 Gear Shift and Select Shaft Disassembly and Assembly....................................................592 Fifth Gear Disassembly and Assembly.....................................................................592 Gear Shift Shaft, Input Shaft and Counter Shaft Removal and Installation................................597 Transaxle Case Disassembly and Assembly.................................................................601 Input & Counter Shaft Components........................................................................603 Input Shaft Disassembly and Assembly....................................................................604 Counter Shaft Disassembly and Assembly..................................................................607 Gear Shift Shaft Components.............................................................................611 High Speed and Low Speed Gear Shift Shafts Inspection...................................................612 5th & Reverse Gear Shift Shafts Disassembly and Assembly................................................612 Differential Components.................................................................................613 Differential Disassembly and Assembly...................................................................614 Differential Adjustment.................................................................................615 Tightening Torque Specification.............................................................................617 Required Service Material...................................................................................618 Special Tool................................................................................................618 SECTION 7B1.....................................................................................................620 General Description.........................................................................................622 Specifications..........................................................................................624 Clutch/Brake/Planetary Gear.............................................................................625 Functions...........................................................................................625 Table of Component Operation............................................................................626 Electronic Shift Control System.........................................................................627 Transmission Control Module (TCM).......................................................................629 Operation of shift solenoid valves, timing solenoid valve and TCC solenoid valve....................630 Automatic gear shift diagram........................................................................631 Diagnosis...................................................................................................632 General Description.....................................................................................632 On-board Diagnostic System..............................................................................633 Precaution in Diagnosing Trouble........................................................................634 Automatic Transaxle Diagnostic Flow Table...............................................................635 “O/D OFF” Lamp Check....................................................................................639 Malfunction Indicator Lamp (MIL) Check..................................................................639 Diagnostic Trouble Code (DTC) Check.....................................................................639 Diagnostic Trouble Code (DTC) Clearance.................................................................640 Diagnostic Trouble Code (DTC) Table.....................................................................641 Fail Safe Table.........................................................................................643 Visual Inspection.......................................................................................645 Automatic Transaxle Basic Check.........................................................................646 Trouble Diagnosis Table.................................................................................647 Trouble diagnosis table-1...........................................................................647 Trouble diagnosis table-2...........................................................................650 Trouble diagnosis table-3...........................................................................652 Road Test...............................................................................................653 Manual Road Test........................................................................................656 Engine Brake Test.......................................................................................657 Stall Test..............................................................................................658 Time Lag Test...........................................................................................659 Line Pressure Test......................................................................................660 “P” Range Test..........................................................................................661 Diagnostic Flow Table A-1: No Gear Shift to O/D.........................................................662 Diagnostic Flow Table A-2: No Lock-Up Occurs............................................................663 Diagnostic Flow Table A-3: “O/D OFF” Lamp Circuit Check (“O/D OFF” Lamp Lights Steadily)................664 Diagnostic Flow Table A-4: “O/D OFF” Lamp Circuit Check (“O/D OFF” Lamp Does Not Light Anytime).........666 Diagnostic Flow Table A-5: TCM Power and Ground Circuit Check...........................................667 DTC P0705 Transmission Range Sensor Circuit Malfunction.................................................669 DTC P0707 Transmission Range Sensor Circuit Low.........................................................672 DTC P0712 Transmission Fluid Temperature Sensor Circuit Low.............................................675 DTC P0713 Transmission Fluid Temperature Sensor Circuit High............................................677 DTC P0717 Input/Turbine Speed Sensor Circuit Malfunction................................................679 DTC P0722 Output Speed Sensor (VSS) Circuit No Signal...................................................681 DTC P0741/P0742 TCC Circuit Performance or Stuck OFF/TCC Circuit Stuck ON...............................684 DTC P0751/P0752/P0756/P0757 Shift Solenoid-A (No.1) Performance or Stuck OFF/Shift Solenoid-A (No.......685 DTC P0785 Timing Solenoid...............................................................................687 DTC P0962 Pressure Control Solenoid Control Circuit Low.................................................689 DTC P0963 Pressure Control Solenoid Control Circuit High................................................691 DTC P0974/P0977 Shift Solenoid-A (No.1) Control Circuit High/Shift Solenoid- B (No.2) Control Cir.......693 DTC P1701 CAN Communication Error.......................................................................695 DTC P1702 Internal Control Module Memory Check Sum Error................................................697 DTC P1703 CAN Invalid Data-TCM..........................................................................697 DTC P2769 Torque Converter Clutch (TCC) Circuit Low.....................................................698 DTC P2770 Torque Converter Clutch (TCC) Circuit High....................................................700 Scan Tool Data..........................................................................................702 Inspection of TCM and Its Circuits......................................................................706 On-Vehicle Service..........................................................................................710 Maintenance Service.....................................................................................710 Fluid level check at normal operating (hot) temperature (Hot check).................................710 Fluid level check at room (cold) temperature (Cold check)...........................................711 Fluid change........................................................................................711 A/T fluid cooler hoses..............................................................................712 Selector Lever..........................................................................................713 Select Cable............................................................................................714 Transmission Range Sensor (Shift Switch)................................................................716 Output Shaft Speed Sensor (VSS).........................................................................717 Input Shaft Speed Sensor................................................................................718 Throttle Position Sensor................................................................................718 Engine Coolant Temperature Sensor.......................................................................719 O/D Off Switch..........................................................................................719 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Timing Solenoid Valve)...................720 Pressure Control Solenoid Valve.........................................................................725 Transmission Control Module (TCM).......................................................................728 A/T Relay...............................................................................................729 Transmission Fluid Temperature Sensor...................................................................730 Differential Side Oil Seal..............................................................................732 Automatic Transaxle Assembly............................................................................734 Unit Repair.................................................................................................737 Precautions.............................................................................................737 Part Inspection and Correction Table....................................................................738 Unit Disassembly........................................................................................739 Components..........................................................................................739 Disassembly/Assembly of Subassembly.....................................................................760 Oil pump assembly...................................................................................761 Direct clutch assembly..............................................................................765 Forward and reverse clutch assembly.................................................................770 2nd brake piston assembly...........................................................................778 Transaxle rear cover assembly (O/D and 2nd coast brake piston)......................................780 Differential Assembly...................................................................................783 Countershaft assembly...............................................................................787 Valve body assembly.................................................................................789 Torque converter housing............................................................................791 Transaxle case......................................................................................794 Adjustment before unit assembly.....................................................................796 Unit Assembly...........................................................................................799 Tightening Torque Specification.............................................................................822 Special Tool................................................................................................823 Required Service Material...................................................................................825 SECTION 7C......................................................................................................826 On-Vehicle Service..........................................................................................827 Clutch Cable............................................................................................827 Clutch Pedal and Clutch Pedal Bracket...................................................................830 Clutch Cover, Clutch Disc and Flywheel..................................................................831 Clutch Release Bearing / Shaft / Bush / Lever...........................................................834 Tightening Torque Specification.............................................................................837 Required Service Material...................................................................................837 Special Tool................................................................................................838 SECTION 7D......................................................................................................840 Unit Repair Overhaul........................................................................................841 Tightening Torque Specification.............................................................................845 Required Service Material...................................................................................846 SECTION 7F......................................................................................................848 General Description.........................................................................................849 Differential Unit.......................................................................................849 Unit Repair Overhaul........................................................................................852 Drive bevel pinion bearing outer race...................................................................856 Differential case assembly..............................................................................856 Differential carrier and drive bevel pinion.............................................................858 Tightening Torque Specification.............................................................................865 Required Service Material...................................................................................865 Special Tool................................................................................................866 SECTION 8B......................................................................................................868 Diagnosis...................................................................................................869 Rear Fog Light..........................................................................................869 On-Vehicle Service..........................................................................................870 Rear Fog Light..........................................................................................870 Rear fog light circuit..............................................................................870 SECTION 8C......................................................................................................872 General Description.........................................................................................873 Combination Meter.......................................................................................873 Diagnosis...................................................................................................874 Low Engine Oil Level Warning Light Symptom Diagnosis for Z13DT Engine (If equipped).....................874 On-Vehicle Service..........................................................................................875 Low Fuel Warning System.................................................................................875 Engine Oil Level Switch for Z13DT Engine (If Equipped)..................................................876 SECTION 8G......................................................................................................878 General Description.........................................................................................879 On-board Diagnostic System for M13 Engine Model.........................................................880 Diagnosis...................................................................................................881 Diagnostic Flow Table for M13 Engine Model..............................................................881 Diagnostic Trouble Code (DTC) Check for M13 Engine Model................................................882 Diagnostic Trouble Code (DTC) Clearance for M13 Engine Model............................................882 Inspection of Immobilizer Control Module and Its Circuits for M13 Engine Model..........................883 DTC B3040 W-line Communication Fail for M13 Engine Model................................................884 DTC B3042 W-line CKT Malf (Short to Ground) for M13 Engine Model........................................885 DTC B3043 W-line CKT Malf (Short to Battery) for M13 Engine Model.......................................886 DTC B3059 No Request from ECM for M13 Engine Model......................................................887 Special Tools...............................................................................................888 SECTION 8G3.....................................................................................................890 General Description.........................................................................................891 Components..............................................................................................891 Operations..............................................................................................891 Wiring Circuit..........................................................................................891 ON-Board Diagnostic System..............................................................................892 Diagnosis...................................................................................................893 Precautions in Diagnosing Troubles......................................................................893 Diagnostic Flow Table...................................................................................894 Diagnostic Trouble Code (DTC) Check.....................................................................895 Diagnostic Trouble Code (DTC) Clearance.................................................................895 Diagnostic Trouble Code (DTC) Table.....................................................................896 Inspection of Immobilizer Control Module and Its Circuits...............................................897 DTC B3040 W-Line Communication Fail.....................................................................899 DTC B3042 W-Line CKT Malf (Short to Ground).............................................................900 DTC B3043 W-Line CKT Malf (Short to Battery)............................................................901 DTC B3059 No Request from ECM...........................................................................902 On-vehicle Service..........................................................................................903 Registration Procedure of Immobilizer System Components.................................................903 How to register ignition key........................................................................903 Procedure after Immobilizer Control Module replacement..............................................903 Procedure after ECM replacement.....................................................................903 Special Tools...............................................................................................904 SECTION 9.......................................................................................................906 Body Structure..............................................................................................907 Front Fender............................................................................................907 Front Bumper and Rear Bumper............................................................................908 Exterior and Interior Trim..................................................................................909 Back Door Emblem........................................................................................909 Panel Clearance.............................................................................................910 Copyright.......................................................................................................912
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