2004-2008 Suzuki Swift Sport RS416 Service Repair Manual- PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2004-2008 Suzuki Swift Sport RS416 Service Repair Manual- PDF DOWNLOAD
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
, and NOTE have special meanings. Pay special attention to the messages highlighted
by these signal words.
WARNING
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
- Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.
- If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
- Do not modify the steering wheel, instrument panel or any other air bag system component on or around air bag system components or wiring. Modifications can adversely affect air bag system performance and lead to injury.
- If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation.
FOREWORD
This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and reassembly of major components
(Unit Repair-Overhaul).
Applicable Model:
SWIFT (RS416) produced at KOSAI plant in Japan with the following vehicle identification numbers
(VINs).
- 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:
2004-2008 Suzuki Swift Sport RS416 Service Repair Manual- PDF DOWNLOAD
Suzuki Swift Sport (RS416) Service Manual 1
IMPORTANT 2
FOREWORD 3
TABLE OF CONTENTS 4
Precautions 5
Precautions 6
Precautions 6
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 6
General Precautions 9
Warning for Wheel (with tire) Removal 12
Warning for Handling Emergency Flat Tire Repair Kit 12
Precautions for Catalytic Converter 12
Precautions for Installing Mobile Communication Equipment 12
Precaution for CAN Communication System 12
Precautions for Electrical Circuit Service 13
Air Bag Warning 15
Air Bag System Service Warning 15
Fastener Caution 15
Suspension Caution 15
Wheels and Tires Caution 15
Precaution for Vehicle Equipped with ESP‚ System 16
Brake Caution 16
Repair Instructions 16
Electrical Circuit Inspection Procedure 16
Intermittent and Poor Connection Inspection 18
General Information 21
General Information 22
General Description 22
Abbreviations 22
Symbols 23
Wire Color Symbols 23
Fasteners Information 24
Vehicle Lifting Points 26
Engine Supporting Points 28
Vehicle Identification Number 28
Engine Identification Number 28
Transmission Identification Number 28
Component Location 29
Warning, Caution and Information Labels Location 29
Maintenance and Lubrication 31
Precautions 31
Precautions for Maintenance and Lubrication 31
Scheduled Maintenance 31
Maintenance Schedule under Normal Driving Conditions 31
Maintenance Recommended under Severe Driving Conditions 32
Repair Instructions 33
Accessory Drive Belt Inspection 33
Accessory Drive Belt Replacement 34
Valve Lash (Clearance) Inspection 34
Engine Oil and Filter Change 34
Engine Coolant Change 35
Exhaust System Inspection 36
Spark Plug Replacement 36
Air Cleaner Filter Inspection 36
Air Cleaner Filter Replacement 36
Fuel Lines and Connections Inspection 36
Fuel Filter Replacement 37
Fuel Tank Inspection 37
PCV Valve Inspection 37
Fuel Evaporative Emission Control System Inspection 37
Brake Discs and Pads Inspection 37
Brake Hoses and Pipes Inspection 37
Brake Fluid Inspection 38
Brake Fluid Replacement 38
Brake Lever and Cable Inspection 38
Clutch Fluid Inspection 38
Tires Inspection 39
Wheel Discs Inspection 39
Wheel Bearing Inspection 39
Suspension System Inspection 39
Steering System Inspection 40
Drive Shaft (Axle) Boots Inspection 40
Manual Transaxle Oil Inspection 40
Manual Transaxle Oil Replacement 40
Automatic Transaxle Fluid Level Inspection 41
Automatic Transaxle Fluid Replacement 41
Automatic Transaxle Fluid Cooler Hose Inspection 41
All Latches, Hinges and Locks Inspection 41
HVAC Air Filter (If Equipped) Inspection 42
HVAC Air Filter (If Equipped) Replacement 42
Final Inspection for Maintenance Service 42
Specifications 43
Tightening Torque Specifications 43
Special Tools and Equipment 43
Recommended Fluids and Lubricants 43
Special Tool 44
Engine 45
Precautions 50
Precautions 50
Precautions for Engine 50
Engine General Information and Diagnosis 51
Precautions 51
Precautions on Engine Service 51
Precaution on On-Board Diagnostic (OBD) System 51
Precautions in Diagnosing Trouble 51
Precautions of ECM Circuit Inspection 52
Precautions of Electric Throttle Body System Calibration 52
General Description 52
Statement on Cleanliness and Care 52
Engine Diagnosis General Description 53
On-Board Diagnostic System Description 53
Data Link Connector (DLC) 56
Engine and Emission Control System Description 56
CAN Communication System Description 57
Air Intake System Description 59
Description of Electric Throttle Body System 59
Description of Electric Throttle Body System Calibration 60
Fuel Cut Control Description 60
Generator Control System Description 61
Electronic Control System Description 62
Engine and Emission Control Input / Output Table 68
Schematic and Routing Diagram 69
Engine and Emission Control System Diagram 69
Component Location 71
Electronic Control System Components Location 71
Diagnostic Information and Procedures 72
Engine and Emission Control System Check 72
Malfunction Indicator Lamp (MIL) Check 75
DTC Check 76
DTC Clearance 77
DTC Table 77
Fail-Safe Table 81
Scan Tool Data 83
Visual Inspection 87
Engine Basic Inspection 88
Engine Symptom Diagnosis 91
MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) 97
Malfunction Indicator Lamp Remains ON after Engine Starts 98
DTC P0010: “A” Camshaft Position Actuator Circuit 99
DTC P0011 / P0012: “A” Camshaft Position – Timing Over-Advanced or System Performance / – Retarded 102
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) 104
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) 106
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance 108
DTC P0102: Mass or Volume Air Flow Circuit Low Input 111
DTC P0103: Mass or Volume Air Flow Circuit High Input 113
DTC P0106: Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance 114
DTC P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low Input 116
DTC P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High Input 117
DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance 119
DTC P0112: Intake Air Temperature Sensor 1 Circuit Low 122
DTC P0113: Intake Air Temperature 1 Sensor Circuit High 124
DTC P0116: Engine Coolant Temperature Circuit Range / Performance 126
DTC P0117: Engine Coolant Temperature Circuit Low 129
DTC P0118: Engine Coolant Temperature Circuit High 131
DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low 133
DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit High 135
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) 138
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) 141
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1) 142
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2) 144
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) 147
DTC P0171 / P0172: Fuel System Too Lean / Rich 148
DTC P0222: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit Low 150
DTC P0223: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit High 152
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected 155
DTC P0327 / P0328: Knock Sensor 1 Circuit Low / High 157
DTC P0335: Crankshaft Position (CKP) Sensor “A” Circuit 159
DTC P0340: Camshaft Position (CMP) Sensor “A” Circuit 161
DTC P0350: Ignition Coil Primary / Secondary Circuit 164
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected 166
DTC P0403: Exhaust Gas Recirculation Control Circuit 168
DTC P0420: Catalyst System Efficiency below Threshold 170
DTC P0443: Evaporative Emission System Purge Control Valve Circuit 172
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit 174
DTC P0500: Vehicle Speed Sensor “A” Malfunction 178
DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low 180
DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit High 182
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance 184
DTC P0616: Starter Relay Circuit Low 185
DTC P0617: Starter Relay Circuit High 186
DTC P0620: Generator Control Circuit 187
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High 189
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High 191
DTC P1510: ECM Back-Up Power Supply Malfunction 193
DTC P1603: TCM Trouble Code Detected 194
DTC P1674: CAN Communication (Bus Off Error) 195
DTC P1676: CAN Communication (Reception Error for TCM) 198
DTC P1678: CAN Communication (Reception Error for BCM) 199
DTC P1685: CAN Communication (Reception Error for ABS/ESP‚ Control Module) 200
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance 202
DTC P2102: Throttle Actuator Control Motor Circuit Low 204
DTC P2103: Throttle Actuator Control Motor Circuit High 205
DTC P2111 / P2112: Throttle Actuator Control System – Stuck Open / Closed 206
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance 207
DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input 209
DTC P2123: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit High Input 211
DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input 214
DTC P2128: Throttle / Pedal Position Sensor / Switch “E” (Sub) Circuit High Input 216
DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage Correlation 218
DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage Correlation 221
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction 223
Inspection of ECM and Its Circuits 225
ECM Power and Ground Circuit Check 244
Fuel Injector Circuit Check 248
Fuel Pump and Its Circuit Check 250
Fuel Pressure Check 253
A/C System Circuits Check 255
Electric Load Signal Circuit Check 259
Radiator Cooling Fan Low Speed Control System Check 261
Radiator Cooling Fan High Speed Control System Check 263
Repair Instructions 266
Idle Speed and IAC Throttle Valve Opening Inspection 266
Special Tools and Equipment 267
Special Tool 267
Aux Emission Control Devices 268
Diagnostic Information and Procedures 268
EGR System Inspection 268
Repair Instructions 268
EVAP Canister Purge Inspection 268
EVAP Canister Purge Valve and Its Circuit Inspection 269
Vacuum Passage Inspection 270
Vacuum Hose and Purge Valve Chamber Inspection 270
EVAP Canister Purge Valve Inspection 270
EVAP Canister Inspection 271
EGR Valve Removal and Installation 271
EGR Valve Inspection 271
PCV Hose Inspection 271
PCV Valve Inspection 272
Special Tools and Equipment 272
Special Tool 272
Engine Electrical Devices 273
Repair Instructions 273
ECM Removal and Installation 273
MAP Sensor Inspection 274
Electric Throttle Body Assembly On-Vehicle Inspection 274
Electric Throttle Body System Calibration 277
APP Sensor Assembly On-Vehicle Inspection 277
APP Sensor Assembly Removal and Installation 277
APP Sensor Assembly Inspection 278
ECT Sensor Removal and Installation 278
ECT Sensor Inspection 279
HO2S-1 and HO2S-2 Heater On-Vehicle Inspection 279
HO2S-1 and HO2S-2 Removal and Installation 279
CMP Sensor Removal and Installation 280
Camshaft Position (CMP) Sensor Inspection 280
CKP Sensor Removal and Installation 281
CKP Sensor Inspection 281
Knock Sensor Removal and Installation 282
Main Relay, Fuel Pump Relay and Starting Motor Control Relay Inspection 282
MAF and IAT Sensor On-Vehicle Inspection 283
MAF and IAT Sensor Removal and Installation 283
MAF and IAT Sensor Inspection 284
Electric Load Current Sensor On-Vehicle Inspection 284
Specifications 285
Tightening Torque Specifications 285
Engine Mechanical 286
General Description 286
Engine Construction Description 286
Camshaft Position Control (VVT Variable Valve Timing) System Description 287
Diagnostic Information and Procedures 289
Compression Check 289
Engine Vacuum Check 290
Valve Lash (Clearance) Inspection 291
Repair Instructions 294
Air Cleaner Components 294
Air Cleaner Element Removal and Installation 294
Air Cleaner Element Inspection and Cleaning 295
Cylinder Head Cover Removal and Installation 295
Throttle Body and Intake Manifold Components 297
Throttle Body On-Vehicle Inspection 298
Electric Throttle Body Assembly Removal and Installation 298
Throttle Body Cleaning 299
Intake Manifold Removal and Installation 299
Engine Mountings Components 301
Engine Assembly Removal and Installation 302
Timing Chain Cover Components 305
Timing Chain Cover Removal and Installation 306
Timing Chain Cover Inspection 308
Oil Control Valve Removal and Installation 308
Oil Control Valve Inspection 309
Timing Chain and Chain Tensioner Components 309
Timing Chain and Chain Tensioner Removal and Installation 310
Timing Chain and Chain Tensioner Inspection 312
Camshaft, Tappet and Shim Components 313
Camshaft, Tappet and Shim Removal and Installation 314
Camshaft, Tappet and Shim Inspection 316
Valves and Cylinder Head Components 319
Valves and Cylinder Head Removal and Installation 320
Valves and Cylinder Head Disassembly and Assembly 322
Valves and Valve Guides Inspection 325
Cylinder Head Inspection 327
Valve Spring Inspection 328
Pistons, Piston Rings, Connecting Rods and Cylinders Components 329
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation 330
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly 331
Cylinders, Pistons and Piston Rings Inspection 332
Piston Pins and Connecting Rods Inspection 334
Crank Pin and Connecting Rod Bearings Inspection 335
Main Bearings, Crankshaft and Cylinder Block Components 338
Main Bearings, Crankshaft and Cylinder Block Removal and Installation 339
Crankshaft Inspection 342
Main Bearings Inspection 344
Sensor Plate Inspection 348
Rear Oil Seal Inspection 348
Flywheel Inspection 348
Cylinder Block Inspection 348
Specifications 349
Tightening Torque Specifications 349
Special Tools and Equipment 351
Recommended Service Material 351
Special Tool 351
Engine Lubrication System 353
General Description 353
Engine Lubrication Description 353
Diagnostic Information and Procedures 354
Oil Pressure Check 354
Repair Instructions 355
Heat Exchanger Components 355
Heat Exchanger On-Vehicle Inspection 356
Heat Exchanger Removal and Installation 356
Oil Pan and Oil Pump Strainer Components 357
Oil Pan and Oil Pump Strainer Removal and Installation 357
Oil Pan and Oil Pump Strainer Cleaning 359
Oil Pump Components 360
Oil Pump Removal and Installation 360
Oil Pump Disassembly and Reassembly 360
Oil Pump Inspection 361
Specifications 363
Tightening Torque Specifications 363
Special Tools and Equipment 363
Recommended Service Material 363
Special Tool 363
Engine Cooling System 364
General Description 364
Cooling System Description 364
Coolant Description 364
Schematic and Routing Diagram 365
Coolant Circulation 365
Diagnostic Information and Procedures 367
Engine Cooling Symptom Diagnosis 367
Repair Instructions 368
Cooling System Components 368
Coolant Level Check 369
Engine Cooling System Inspection and Cleaning 369
Cooling System Draining 369
Cooling System Flush and Refill 370
Cooling Water Pipes or Hoses Removal and Installation 370
Thermostat Removal and Installation 371
Thermostat Inspection 371
Radiator Cooling Fan Motor On-Vehicle Inspection 372
Radiator Cooling Fan Relay Inspection 372
Radiator Cooling Fan Removal and Installation 373
Radiator On-Vehicle Inspection and Cleaning 373
Radiator Removal and Installation 373
Water Pump Removal and Installation 374
Water Pump Inspection 374
Specifications 375
Tightening Torque Specifications 375
Special Tools and Equipment 375
Recommended Service Material 375
Fuel System 376
Precautions 376
Precautions on Fuel System Service 376
General Description 376
Fuel System Description 376
Fuel Delivery System Description 376
Fuel Pump Description 377
Schematic and Routing Diagram 377
Fuel Delivery System Diagram 377
Diagnostic Information and Procedures 377
Fuel Pressure Inspection 377
Fuel Cut Operation Inspection 378
Repair Instructions 379
Fuel System Components 379
Fuel Hose Disconnecting and Reconnecting 380
Fuel Pressure Relief Procedure 382
Fuel Leakage Check Procedure 382
Fuel Lines On-Vehicle Inspection 382
Fuel Pipe Removal and Installation 382
Fuel Injector On-Vehicle Inspection 383
Fuel Injector Removal and Installation 383
Fuel Injector Inspection 384
Fuel Filler Cap Inspection 385
Fuel Tank Inlet Valve Removal and Installation 386
Fuel Tank Inlet Valve Inspection 387
Fuel Tank Removal and Installation 387
Fuel Tank Inspection 388
Fuel Tank Purging Procedure 389
Fuel Pump On-Vehicle Inspection 389
Fuel Pump Assembly Removal and Installation 389
Main Fuel Level Sensor Removal and Installation 390
Fuel Pump Inspection 391
Specifications 391
Tightening Torque Specifications 391
Special Tools and Equipment 392
Special Tool 392
Ignition System 393
General Description 393
Ignition System Construction 393
Schematic and Routing Diagram 394
Ignition System Wiring Circuit Diagram 394
Component Location 395
Ignition System Components Location 395
Diagnostic Information and Procedures 396
Ignition System Symptom Diagnosis 396
Reference Waveform of Ignition System 396
Ignition System Check 396
Ignition Spark Test 398
Repair Instructions 398
High-Tension Cord Removal and Installation 398
High-Tension Cord Inspection 399
Spark Plug Removal and Installation 399
Spark Plug Inspection 399
Ignition Coil Assembly (Including ignitor) Removal and Installation 400
Ignition Coil Assembly (Including ignitor) Inspection 400
Ignition Timing Inspection 400
Specifications 401
Tightening Torque Specifications 401
Special Tools and Equipment 401
Special Tool 401
Starting System 402
Schematic and Routing Diagram 402
Cranking System Circuit Diagram 402
Diagnostic Information and Procedures 402
Cranking System Symptom Diagnosis 402
Cranking System Test 404
Repair Instructions 405
Starting Motor Dismounting and Remounting 405
Starting Motor Components 406
Starting Motor Inspection 407
Specifications 410
Cranking System Specifications 410
Tightening Torque Specifications 410
Special Tools and Equipment 410
Recommended Service Material 410
Charging System 411
General Description 411
Battery Description 411
Generator Description 412
Diagnostic Information and Procedures 414
Battery Inspection 414
Generator Symptom Diagnosis 414
Generator Test (Undercharged Battery Check) 415
Generator Test (Overcharged Battery Check) 416
Repair Instructions 416
Jump Starting in Case of Emergency 416
Battery Dismounting and Remounting 417
Water Pump / Generator Drive Belt Tension Inspection and Adjustment 417
Water Pump / Generator Drive Belt Removal and Installation 418
Generator Unit Components 419
Generator Dismounting and Remounting 419
Generator Components 420
Generator Inspection 421
Specifications 423
Charging System Specifications 423
Tightening Torque Specifications 423
Exhaust System 424
General Description 424
Exhaust System Description 424
Diagnostic Information and Procedures 424
Exhaust System Check 424
Repair Instructions 425
Exhaust System Components 425
Exhaust Manifold Removal and Installation 426
Exhaust Pipe and Muffler Removal and Installation 427
Specifications 428
Tightening Torque Specifications 428
Suspension 429
Precautions 431
Precautions 431
Precautions on Suspension 431
Suspension General Diagnosis 432
Diagnostic Information and Procedures 432
Suspension, Wheels and Tires Symptom Diagnosis 432
Front Suspension 434
General Description 434
Front Suspension Construction 434
Front Wheel Alignment Construction 435
Repair Instructions 435
Front Wheel Alignment Inspection and Adjustment 435
Front Strut Assembly Components 437
Front Strut Assembly Removal and Installation 437
Front Strut Assembly Disassembly and Assembly 439
Front Strut Assembly Check 440
Front Wheel Hub and Steering Knuckle Components 441
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation 441
Front Wheel Hub, Disc, Nut and Bearing Check 445
Suspension Control Arm / Bushing Removal and Installation 445
Suspension Control Arm / Bushing Disassembly and Assembly 446
Suspension Control Arm / Steering Knuckle Check 447
Suspension Control Arm Bushing Check 447
Suspension Control Arm Joint Check 447
Front Suspension Frame, Stabilizer Bar and/or Bushings Components 448
Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation 448
Front Suspension Frame Check 452
Front Stabilizer Bar, Bushing and/or Joint Check 452
Front Suspension Fasteners Check 452
Specifications 453
Tightening Torque Specifications 453
Special Tools and Equipment 454
Special Tool 454
Rear Suspension 455
General Description 455
Rear Suspension Construction 455
Repair Instructions 456
Rear Wheel Alignment Inspection 456
Rear Shock Absorber Removal and Installation 456
Rear Shock Absorber Inspection 457
Rear Shock Absorber Bush Removal and Installation 458
Rear Shock Absorber Bush Inspection 458
Rear Coil Spring Removal and Installation 458
Spring Upper Seat / Spring Lower Seat Inspection 459
Spring Upper Seat and Lower Seat Removal and Installation 460
Rear Axle Removal and Installation 460
Trailing Arm, Rear Axle and Coil Spring Inspection 463
Rear Axle Bush Inspection 463
Rear Wheel Hub Components 464
Rear Wheel Hub Removal and Installation 464
Rear Wheel Disc, bolt and Bearing Inspection 465
Spindle Removal and Installation 466
Spindle Inspection 467
Rear Suspension Fasteners Inspection 467
Specifications 467
Tightening Torque Specifications 467
Special Tools and Equipment 467
Special Tool 467
Wheels and Tires 468
Precautions 468
Precaution for Emergency Flat Tire Repair Kit 468
General Description 468
Tires Description 468
Wheels Description 469
Irregular and/or Premature Wear Description 470
Wear Indicators Description 470
Radial Tire Waddle Description 471
Radial Tire Lead / Pull Description 472
Balancing Wheels Description 472
Repair Instructions 473
General Balance Procedures 473
Tire Rotation 473
Wheel Removal and Installation 474
Tire Mounting and Dismounting 475
Tire Repair 475
Tire Repair for Emergency Repaired-Tire with Sealant 475
Specifications 476
Wheels and Tires Specifications 476
Tightening Torque Specifications 476
Driveline / Axle 477
Precautions 478
Precautions 478
Precautions for Driveline / Axle 478
Drive Shaft / Axle 479
General Description 479
Front Drive Shaft Construction 479
Component Location 479
Front Drive Shaft Assembly Components Location 479
Diagnostic Information and Procedures 480
Front Drive Shaft Symptom Diagnosis 480
Repair Instructions 481
Front Drive Shaft Components 481
Front Drive Shaft Assembly On-Vehicle Inspection 482
Front Drive Shaft Assembly Removal and Installation 482
Front Drive Shaft Disassembly and Reassembly 484
Center Shaft and Center Bearing Support Disassembly and Reassembly 492
Specifications 493
Tightening Torque Specifications 493
Special Tools and Equipment 493
Recommended Service Material 493
Special Tool 493
Brakes 495
Precautions 498
Precautions 498
Precautions for Brakes 498
Brake Control System and Diagnosis 499
Precautions 499
Precautions on Brake 499
General Description 499
Brakes Construction 499
Brake Pedal Foot Protection System Construction 500
Front Brake Hose / Pipe Construction 501
Rear Brake Hose / Pipe Construction 502
Diagnostic Information and Procedures 502
Brakes Diagnosis Note 502
Brakes Symptom Diagnosis 503
Repair Instructions 505
Brake Pedal Components 505
Brake Pedal Free Height Inspection 505
Brake Pedal Play Inspection 505
Excessive Pedal Travel Inspection 506
Brake Fluid Level Inspection 506
Stop Light Switch Adjustment 506
Air Bleeding of Brake System 507
Front Brake Hose / Pipe Removal and Installation 508
Rear Brake Hose / Pipe Removal and Installation 508
Brake Hose and Pipe Inspection 509
Master Cylinder Components 509
Master Cylinder Assembly Removal and Installation 510
Master Cylinder Reservoir Removal and Installation 511
Master Cylinder Assembly Disassembly and Assembly 512
Master Cylinder Assembly Inspection 513
Brake Booster Components 513
Booster Operation Inspection 514
Brake Booster Removal and Installation 515
Brake Booster Inspection and Adjustment 516
Specifications 516
Tightening Torque Specifications 516
Special Tools and Equipment 516
Recommended Service Material 516
Front Brakes 517
Repair Instructions 517
Front Disc Brake Components 517
Front Disc Brake Pad On-Vehicle Inspection 518
Front Disc Brake Pad Removal and Installation 518
Front Disc Brake Pad Inspection 519
Front Disc Brake Caliper Removal and Installation 519
Front Disc Brake Caliper Disassembly and Assembly 520
Front Disc Brake Caliper Inspection 522
Front Brake Disc Removal and Installation 522
Front Brake Disc Inspection 523
Specifications 524
Tightening Torque Specifications 524
Special Tools and Equipment 524
Recommended Service Material 524
Special Tool 524
Rear Brakes 525
Repair Instructions 525
Rear Disc Brake Components 525
Rear Disc Brake Pad Removal and Installation 526
Rear Disc Brake Caliper Removal and Installation 527
Rear Disc Brake Pad Inspection 530
Rear Disc Brake Caliper Disassembly and Assembly 530
Rear Disc Brake Caliper Inspection 532
Rear Flexible Hose Removal and Installation 532
Rear Brake Disc Removal and Installation 533
Rear Brake Disc Inspection 533
Specifications 534
Tightening Torque Specifications 534
Special Tools and Equipment 535
Recommended Service Material 535
Special Tool 535
Parking Brake 536
General Description 536
Parking Brake Cable Construction 536
Repair Instructions 537
Parking Brake Inspection and Adjustment 537
Parking Brake Cable Removal and Installation 538
Parking Brake Lever Removal and Installation 538
Specifications 539
Tightening Torque Specifications 539
ABS 540
Precautions 540
Precautions in Diagnosing Troubles 540
Precautions in On-Vehicle Service 540
Precautions in Hydraulic Unit Operation Check 540
General Description 541
ABS Description 541
ABS Hydraulic Unit / Control Module Assembly Description 541
CAN Communication System Description 542
Schematic and Routing Diagram 543
ABS Schematic 543
ABS Wiring Circuit Diagram 544
Component Location 546
ABS Components Location 546
Front Wheel Speed Sensor Components Location 546
Rear Wheel Speed Sensor Components Location 547
Diagnostic Information and Procedures 547
ABS Check 547
ABS Warning Light Check 549
EBD Warning Light (Brake Warning Light) Check 549
DTC Check 550
DTC Table 550
DTC Clearance 551
Scan Tool Data 551
ABS Warning Light Does Not Come ON at Ignition Switch ON 552
ABS Warning Light Comes ON Steady 553
EBD Warning Light (Brake Warning Light) Comes ON Steady 554
Serial Data Link Circuit Check 555
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring 557
DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front / Left-Front / Right-Rear / Left-Rear Inlet Solenoid Circuit, Right-Front / Left-Front / Right-Rear / Left-Rear Outlet Solenoid Circuit 559
DTC C1057: Power Source Circuit 560
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit 561
DTC C1063: Solenoid Valve Power Supply Driver Circuit 562
DTC C1071: ABS Control Module 563
DTC U1073: Control Module Communication Bus Off 564
DTC U1100: Lost Communication with ECM (Reception Error) 566
Repair Instructions 567
ABS Hydraulic Unit Operation Check 567
ABS Hydraulic Unit / Control Module Assembly Components 568
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection 568
ABS Hydraulic Unit / Control Module Assembly Removal and Installation 568
Front / Rear Wheel Speed Sensor On-Vehicle Inspection 570
Front Wheel Speed Sensor Removal and Installation 571
Front Wheel Speed Sensor Inspection 571
Rear Wheel Speed Sensor Removal and Installation 572
Rear Wheel Speed Sensor Inspection 573
Front Wheel Encoder On-Vehicle Inspection 573
Front wheel Encoder Removal and Installation 573
Rear Wheel Encoder On-Vehicle Inspection 573
Rear Wheel Encoder Removal and Installation 573
Specifications 574
Tightening Torque Specifications 574
Special Tools and Equipment 574
Special Tool 574
Electronic Stability Program 575
Precautions 575
Precautions in Diagnosing Troubles 575
Precautions in On-Vehicle Service 575
Precautions in Hydraulic Unit Operation Check 575
Precautions in Sensor Calibration 575
Precautions in Speedometer Test or Other Tests 576
General Description 576
Electronic Stability Program Description 576
Electronic Stability Program Construction 577
ESP‚ Hydraulic Unit / Control Module Assembly Description 579
Warning Lamp, Indicator Lamp Description 580
CAN Communication System Description 580
CAN Communication System For Electronic Stability Program Description 581
Schematic and Routing Diagram 582
Electronic Stability Program Schematic 582
Electronic Stability Program Wiring Circuit Diagram 583
Component Location 585
Electronic Stability Program Component Location 585
Diagnostic Information and Procedures 586
Electronic Stability Program System Check 586
ESP‚ Warning lamp Check 588
ABS Warning Lamp Check 588
EBD Warning Lamp (Brake Warning Lamp) Check 589
DTC Check 589
DTC Table 589
DTC Clearance 592
Fail-Safe Table 593
Scan Tool Data 594
Visual Inspection 595
ESP‚ Warning Lamp Does Not Come ON at Ignition Switch ON 595
ESP‚ Warning Lamp Comes ON Steady 596
ABS Warning Lamp Does Not Come ON at Ignition Switch ON 597
ABS Warning Lamp Comes ON Steady 598
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady 598
Serial Data Link Circuit Check 600
DTC C1016: Stop Lamp Switch Circuit Failure 602
DTC C1017 / C1023: Yaw Rate / G Sensor Assembly Failure 603
DTC C1018: Brake Fluid Level Switch Failure 604
DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure 605
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed Sensor Circuit or Encoder Failure 606
DTC C1024: Steering Angle Sensor Circuit Failure 608
DTC C1027: ESP‚ OFF Switch Circuit Failure 608
DTC C1028: Master Cylinder Pressure Sensor Circuit Failure 609
DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure 610
DTC C1037: Steering Angle Sensor Power Supply Failure 611
DTC C1038: Steering Angle Sensor Detect Rolling Counter Failure from ESP‚ Control Module 612
DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure 613
DTC C1040: Stability Control System Function Failure 613
DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Solenoid Circuit Failure 614
DTC C1057: ESP‚ Control Module Power Supply Circuit Failure 615
DTC C1061: Pump Motor and/or Motor Driver Circuit Failure 616
DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure 617
DTC 1071: ESP‚ Control Module Internal Defect 618
DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly 619
DTC C1075 / 1076 / 1078: Sensor Calibration Incomplete 620
DTC C1090: Invalid Communication with ECM 621
DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control Communication with ECM 622
DTC U1073: Control Module Communication Bus Off 623
DTC U1100: Lost Communication with ECM (Reception Error) 624
DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error) 625
DTC U1140: Lost Communication with BCM (Reception Error) 626
Repair Instructions 628
ESP‚ Hydraulic Unit Operation Check 628
Sensor Calibration 628
ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection 629
ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation 630
Front / Rear Wheel Speed Sensor On-Vehicle Inspection 631
Front Wheel Speed Sensor Removal and Installation 632
Front Wheel Speed Sensor Inspection 633
Rear Wheel Speed Sensor Removal and Installation 633
Rear Wheel Speed Sensor Inspection 634
Front Wheel Encoder On-Vehicle Inspection 635
Front Wheel Encoder Removal and Installation 635
Rear Wheel Encoder On-Vehicle Inspection 635
Rear Wheel Encoder Removal and Installation 635
Master Cylinder Pressure Sensor On-Vehicle Inspection 635
Yaw Rate / G Sensor Assembly On-Vehicle Inspection 636
Yaw Rate / G Sensor Assembly Removal and Installation 637
Yaw Rate / G Sensor Inspection 638
Steering Angle Sensor On-Vehicle Inspection 638
Steering Angle Sensor Removal and Installation 639
Steering Angle Sensor Inspection 639
ESP‚ OFF Switch Removal and Installation 639
ESP‚ OFF Switch Inspection 639
Specifications 640
Tightening Torque Specifications 640
Special Tools and Equipment 640
Special Tool 640
Transmission / Transaxle 641
Precautions 644
Precautions 644
Precautions on Transmission / Transaxle 644
Automatic Transmission/Transaxle 645
Precautions 645
Precautions in Diagnosing Trouble 645
Precautions for Disassembly and Reassembly 645
General Description 647
A/T Description 647
Clutch / Brake / Planetary Gear Function of Automatic Transaxle 650
Table of Component Operation 651
Brake Interlock System Construction 652
A/T Diagnosis General Description 652
On-Board Diagnostic System Description 652
CAN Communication System Description 653
Schematic and Routing Diagram 654
Transmission Control Module (TCM) Wiring Diagram 654
Automatic Gear Shift Table 656
Component Location 657
Electronic Shift Control System Components Location 657
Diagnostic Information and Procedures 659
A/T System Check 659
Visual Inspection 662
Malfunction Indicator Lamp (MIL) Check 662
Transmission Warning Light Check 662
DTC Table 663
DTC Check 664
DTC Clearance 664
Fail-Safe Table 665
Scan Tool Data 667
A/T Basic Check 670
Road Test 671
Manual Road Test 673
Engine Brake Test 674
Stall Test 674
Time Lag Test 675
Line Pressure Test 676
“P” Range Test 677
A/T Symptom Diagnosis 678
No Gear Shift to 4th gear 685
No Lock-Up Occurs 686
Transmission Warning Light Circuit Check – Light Does Not Come “ON” at Ignition Switch ON 687
Transmission Warning Light Circuit Check – Light Remains “ON” at Ignition Switch ON 687
DTC P0602: Control Module Programming Error 688
DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL input) 688
DTC P0707: Transmission Range Sensor Circuit Low 690
DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low 692
DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High 693
DTC P0717: Input / Turbine Speed Sensor “A” Circuit Malfunction 695
DTC P0722: Output Speed Sensor Circuit No Signal 696
DTC P0787: Shift / Timing Solenoid Low 698
DTC P0788: Shift / Timing Solenoid High 700
DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance 702
DTC P0962: Pressure Control Solenoid “A” Control Circuit Low 704
DTC P0963: Pressure Control Solenoid “A” Control Circuit High 706
DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low 708
DTC P0974 / P0977: Shift Solenoid “A” / Shift Solenoid “B” Control Circuit High 710
DTC P1702: Internal Control Module Memory Check Sum Error 712
DTC P1703: Can Invalid Data – TCM 712
DTC P1723: Range Select Switch Malfunction 713
DTC P1774: CAN Communication Bus Off 715
DTC P1777: TCM Lost Communication with ECM (Reception Error) 717
DTC P1778: TCM Lost Communication with BCM (Reception Error) 718
DTC P1878: Torque Converter Clutch Shudder 719
DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance 720
DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High 722
DTC P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit Low 724
Inspection of TCM and Its Circuits 726
TCM Power and Ground Circuit Check 730
Brake Interlock System Inspection 731
Repair Instructions 732
Learning Control Initialization 732
A/T Fluid Level Check 733
A/T Fluid Change 734
Select Lever Components 734
Select Lever Assembly Removal and Installation 734
Select Lever Knob Installation 734
Select Lever Inspection 735
“3” Position Switch Inspection 735
Shift Lock Solenoid Inspection 735
Shift Lock Solenoid Replacement 735
Select Cable Components 736
Select Cable Removal and Installation 736
Select Cable Adjustment 737
Key Interlock Cable Removal and Installation 737
Transmission Range Sensor (Shift Switch) Inspection and Adjustment 739
Output Shaft Speed Sensor Removal and Installation 740
Output Shaft Speed Sensor Inspection 740
Input Shaft Speed Sensor Removal and Installation 740
Input Shaft Speed Sensor Inspection 741
Transmission Fluid Temperature Sensor Removal and Installation 741
Transmission Fluid Temperature Sensor Inspection 742
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation 742
Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection 743
Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation 745
Pressure Control Solenoid Valve Inspection 745
Transmission Control Module (TCM) Removal and Installation 746
A/T Relay Inspection 747
Differential Side Oil Seal Replacement 747
A/T Fluid Cooler Hoses Replacement 748
Automatic Transaxle Unit Components 749
Automatic Transaxle Unit Dismounting and Remounting 750
Automatic Transaxle Assembly Components 752
Automatic Transaxle Unit Disassembly 754
Oil Pump Assembly Components 765
Oil Pump Assembly Disassembly and Reassembly 766
Oil Pump Assembly Inspection 766
Direct Clutch Assembly Components 768
Direct Clutch Assembly Preliminary Check 768
Direct Clutch Assembly Disassembly and Reassembly 769
Direct Clutch Assembly Inspection 771
Forward and Reverse Clutch Assembly Components 772
Forward and Reverse Clutch Assembly Preliminary Check 773
Forward and Reverse Clutch Assembly Disassembly and Reassembly 773
Forward and Reverse Clutch Assembly Inspection 777
2nd Brake Piston Assembly Components 778
2nd Brake Piston Assembly Disassembly and Reassembly 778
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components 779
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly 780
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection 781
Countershaft Assembly Components 782
Countershaft Assembly Disassembly and Reassembly 782
Valve Body Assembly Components 783
Valve Body Assembly Disassembly and Reassembly 784
Differential Assembly Components 785
Differential Assembly Disassembly and Reassembly 786
Differential Assembly Inspection 787
Torque Converter Housing Disassembly and Reassembly 788
Transaxle Case Disassembly and Reassembly 790
Automatic Transaxle Unit Inspection and Adjustment 791
Automatic Transaxle Unit Assembly 794
Specifications 811
Tightening Torque Specifications 811
Special Tools and Equipment 812
Recommended Service Material 812
Special Tool 812
Manual Transmission/Transaxle 815
General Description 815
Manual Transaxle Construction and Servicing 815
Diagnostic Information and Procedures 817
Manual Transaxle Symptom Diagnosis 817
Repair Instructions 817
Manual Transaxle Oil Change 817
Differential Side Oil Seal Replacement 818
Gear Shift Control Lever and Cable Components 819
Gear Shift Control Lever and Cable Removal and Installation 820
Gear Select Control Cable Adjustment 820
Back Up Light Switch Removal and Installation 821
Back Up Light Switch Inspection 821
Manual Transaxle Unit Components 822
Manual Transaxle Unit Dismounting and Remounting 823
Gear Shift and Select Shaft Assembly Components 825
Gear Shift and Select Shaft Assembly Removal and Installation 825
Gear Shift and Select Shaft Disassembly and Assembly 826
Manual Transaxle Assembly Components 827
Fifth Gear Disassembly and Assembly 828
Manual Transaxle Assembly Disassembly and Reassembly 830
Transaxle Right Case Disassembly and Assembly 837
Transaxle Left Case Disassembly and Assembly 838
Input Shaft and Countershaft Components 839
Input Shaft Assembly Disassembly and Reassembly 840
Countershaft Assembly Disassembly and Reassembly 842
Synchronizer Parts Inspection 845
Gear Shift Shaft Components 845
5th and Reverse Gear Shift Shafts Disassembly and Assembly 846
Gear Shift Shaft and Fork Inspection 846
Differential Components 847
Differential Disassembly and Assembly 847
Specifications 849
Tightening Torque Specifications 849
Special Tools and Equipment 850
Recommended Service Material 850
Special Tool 850
Clutch 853
General Description 853
Clutch Construction 853
Diagnostic Information and Procedures 854
Clutch System Symptom Diagnosis 854
Repair Instructions 854
Clutch Pedal Inspection 854
Clutch Fluid Level Inspection 855
Air Bleeding of Clutch System 855
Clutch Pedal Position (CPP) Switch Removal and Installation 856
Clutch Pedal Position (CPP) Switch Inspection and Adjustment 857
Clutch Fluid Pipe and Hose Components 857
Clutch Fluid Pipe Removal and Installation 858
Clutch Fluid Pipe Inspection 858
Clutch Master Cylinder Removal and Installation 858
Clutch Operating Cylinder Removal and Installation 859
Clutch Operating Cylinder Inspection 859
Clutch Pedal and Clutch Pedal Bracket Components 859
Clutch Cover, Clutch Disc and Flywheel Components 860
Clutch Cover, Clutch Disc and Flywheel Removal and Installation 860
Clutch Cover, Clutch Disc and Flywheel Inspection 862
Clutch Release System Removal and Installation 863
Clutch Release System Inspection 865
Specifications 865
Tightening Torque Specifications 865
Special Tools and Equipment 866
Recommended Service Material 866
Special Tool 866
Steering 867
Precautions 869
Precautions 869
Precautions on Steering 869
Steering General Diagnosis 870
Precautions 870
Precautions for Steering Diagnosis 870
Diagnostic Information and Procedures 871
Steering Symptom Diagnosis 871
Steering Wheel and Column 872
Precautions 872
Service Precautions of Steering Wheel and Column 872
General Description 872
Steering Wheel and Column Construction 872
Diagnostic Information and Procedures 873
Checking Steering Column for Accident Damage 873
Repair Instructions 874
Steering Wheel and Column Construction 874
Steering Wheel Removal and Installation 875
Contact Coil Cable Assembly Removal and Installation 876
Centering Contact Coil Cable Assembly 877
Contact Coil Cable Assembly Inspection 877
Steering Angle Sensor Removal and Installation 877
Steering Angle Sensor Inspection 877
Steering Column Removal and Installation 878
Steering Column Inspection 879
Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model) 880
Steering Lock Assembly (Ignition Switch) Removal and Installation 880
Steering Lower Shaft Removal and Installation 881
Specifications 882
Tightening Torque Specifications 882
Special Tools and Equipment 882
Special Tool 882
Power Assisted Steering System 883
Precautions 883
Steering System Note 883
Precautions in Diagnosing Troubles 883
General Description 884
P/S System Description 884
EPS Diagnosis General Description 885
On-Board Diagnostic System Description 885
Schematic and Routing Diagram 886
EPS System Wiring Circuit Diagram 886
Diagnostic Information and Procedures 887
EPS System Check 887
“EPS” Warning Light Check 890
DTC Check 890
DTC Clearance 891
DTC Table 891
Scan Tool Data 893
Visual Inspection 894
P/S System Symptom Diagnosis 894
Serial Data Link Circuit Check 895
“EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts 897
“EPS” Warning Light Remains ON Steady after Engine Starts 898
DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation 899
DTC C1114: Steering Torque Sensor Reference Power Supply Circuit 901
DTC C1117: Steering Torque Sensor Failure Signal Circuit Low 903
DTC C1118: Steering Torque Sensor Failure Signal Circuit High 904
DTC C1119: Steering Torque Sensor Power Supply Circuit 906
DTC C1121 / C1123 / C1124: VSS Circuit Failure 908
DTC C1122: Engine Speed Signal 910
DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure 912
DTC C1153: P/S Control Module Power Supply Circuit Voltage Low 914
DTC C1155: P/S Control Module Failure 915
P/S Control Module Power Supply and Ground Circuit Check 916
Inspection of P/S Control Module and Its Circuits 917
Steering Wheel Play Check 921
Steering Force Check 921
Repair Instructions 922
Steering Gear Case Assembly Components 922
Tie-Rod End Boot On-Vehicle Inspection 923
Tie-Rod End Removal and Installation 923
Tie-Rod End Inspection 924
Steering Shaft Joint On-Vehicle Inspection 924
Steering Gear Case Assembly Removal and Installation 924
Steering Rack Boot Inspection 925
Tie-Rod / Rack Boot Removal and Installation 925
Steering Rack Plunger Removal and Installation 927
Steering Rack Plunger Inspection 927
P/S Control Module Removal and Installation 928
Torque Sensor and Its Circuit Inspection 928
P/S Motor and Its Circuit Inspection 929
Specifications 930
Tightening Torque Specifications 930
Special Tools and Equipment 931
Recommended Service Material 931
Special Tool 931
HVAC 933
Precautions 936
Precautions 936
Precautions on HVAC 936
Heater and Ventilation 937
General Description 937
Heater and Ventilation Construction 937
Schematic and Routing Diagram 938
Heater and Ventilation Wiring Circuit Diagram 938
Diagnostic Information and Procedures 939
Heater and Ventilation Symptom Diagnosis 939
Repair Instructions 940
HVAC Unit Components 940
HVAC Unit Removal and Installation 940
Blower Motor Removal and Installation 940
Blower Motor Inspection 940
Blower Motor Resistor Removal and Installation 941
Blower Motor Resistor Inspection 941
Blower Motor Relay Inspection 942
HVAC Control Unit Components 942
HVAC Control Unit Removal and Installation 943
Blower Speed Selector Inspection 945
Air Intake Selector Inspection 945
Air Intake Control Actuator Removal and Installation 945
Air Intake Control Actuator Inspection 946
Center Ventilation Louver Removal and Installation 946
Side Ventilation Louver Removal and Installation 947
HVAC Air Filter Removal and Installation (If Equipped) 948
HVAC Air Filter Inspection (If Equipped) 948
Air Conditioning System 949
Manual Type 949
Precautions 949
A/C System Caution 949
Precautions on Servicing A/C System 949
General Description 951
Refrigerant Type Identification 951
Sub-Cool A/C System Description 952
A/C Operation Description 952
Schematic and Routing Diagram 953
Major Components of A/C System 953
A/C System Wiring Diagram 954
Diagnostic Information and Procedures 955
A/C System Symptom Diagnosis 955
Abnormal Noise Symptom Diagnosis of A/C System 957
A/C System Performance Inspection 958
A/C System Inspection at ECM 963
Repair Instructions 964
Operation Procedure for Refrigerant Charge 964
Condenser Assembly On-Vehicle Inspection 969
Condenser Assembly Removal and Installation 969
Receiver/Dryer Removal and Installation 970
HVAC Unit Components 971
HVAC Unit Removal and Installation 972
Evaporator Inspection 972
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation 973
Evaporator Thermistor (Evaporator Temperature Sensor) Inspection 973
Expansion Valve Removal and Installation 974
Expansion Valve Inspection 974
A/C Refrigerant Pressure Sensor and Its Circuit Inspection 974
A/C Refrigerant Pressure Sensor Removal and Installation 974
A/C Switch Inspection 975
Compressor Relay Inspection 975
Compressor Drive Belt Inspection and Adjustment 975
Compressor Drive Belt Removal and Installation 976
Compressor Assembly Removal and Installation 976
Compressor Assembly Components 977
Magnet Clutch Inspection 977
Magnet Clutch Removal and Installation 977
Relief Valve Inspection 979
Relief Valve Removal and Installation 980
Specifications 980
Tightening Torque Specifications 980
Special Tools and Equipment 981
Recommended Service Material 981
Special Tool 981
Automatic Type 982
Precautions 982
A/C System Caution 982
Precautions in Diagnosing Trouble 982
Precautions on Servicing A/C System 982
General Description 982
Auto A/C System Description 982
HVAC Control Module Operation Description 984
Refrigerant Type Identification 984
Sub-Cool A/C System Description 984
A/C Operation Description 984
On-Board Diagnostic System Description 985
Schematic and Routing Diagram 985
Major Components of A/C System 985
A/C System Wiring Diagram 986
Diagnostic Information and Procedures 987
A/C System Symptom Diagnosis 987
Abnormal Noise Symptom Diagnosis of A/C System 990
DTC Check 990
DTC Clearance 991
DTC Table 992
Fail-Safe Table 993
Scan Tool Data 994
Air Conditioning System Check 995
Visual Inspection 997
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction 997
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction 998
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction1000
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction1001
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction1003
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction1005
DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction1008
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction1010
DTC B1546: A/C Refrigerant Pressure Malfunction1011
DTC B1551: Serial Communication Circuit Malfunction1011
DTC B1552: Serial Communication Signal Malfunction1012
DTC B1553: CAN Communication Signal Malfunction1013
DTC B1557: Vehicle Speed Sensor Signal Malfunction1013
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction1014
DTC B1562: Outside Air Temperature Sensor Signal Malfunction1014
DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction1014
Inspection of HVAC Control Module and Its Circuit1015
A/C System Performance Inspection1018
A/C System Inspection at ECM1018
Repair Instructions1019
Operation Procedure for Refrigerant Charge1019
HVAC Unit Components1020
HVAC Unit Removal and Installation1021
Temperature Control Actuator Removal and Installation1021
Temperature Control Actuator Inspection1021
Air Flow Control Actuator Removal and Installation1022
Air Flow Control Actuator Inspection1022
Air Intake Control Actuator Removal and Installation1023
Air Intake Control Actuator Inspection1023
Actuator Linkage Inspection1024
Blower Motor Controller Removal and Installation1024
Blower Motor Controller Inspection1024
HVAC Control Module Removal and Installation1025
Sunload Sensor Removal and Installation1025
Sunload Sensor Inspection1025
Outside Air Temperature Sensor Removal and Installation1025
Outside Air Temperature Sensor Inspection1025
Inside Air Temperature Sensor Removal and Installation1026
Inside Air Temperature Sensor Inspection1026
Condenser Assembly On-Vehicle Inspection1026
Condenser Assembly Removal and Installation1026
Receiver/Dryer Removal and Installation1026
Evaporator Inspection1026
Evaporator Temperature Sensor Removal and Installation1026
Evaporator Temperature Sensor Inspection1026
Expansion Valve Removal and Installation1026
Expansion Valve Inspection1026
A/C Refrigerant Pressure Sensor and Its Circuit Inspection1026
A/C Refrigerant Pressure Sensor Removal and Installation1026
Compressor Relay Inspection1026
Compressor Drive Belt Inspection and Adjustment1026
Compressor Drive Belt Removal and Installation1027
Compressor Assembly Removal and Installation1027
Compressor Assembly Components1027
Magnet Clutch Removal and Installation1027
Magnet Clutch Inspection1027
Relief Valve Inspection1027
Special Tools and Equipment1027
Special Tool1027
Restraint1029
Precautions1031
Precautions1031
Precautions on Restraint1031
Seat Belts1032
Precautions1032
Precautions on Service and Diagnosis of Seat Belt1032
General Description1032
Seat Belt Construction1032
Diagnostic Information and Procedures1033
Repair and Inspection Required after Accident1033
Repair Instructions1034
Front Seat Belt Components1034
Front Seat Belt Removal and Installation1035
Front Seat Belt Inspection1035
Rear Seat Belt Components1037
Rear Seat Belt Removal and Installation1038
Rear Seat Belt Inspection1038
Specifications1038
Tightening Torque Specifications1038
Air Bag System1039
Precautions1039
Precautions on Service and Diagnosis of Air Bag System1039
Precautions on Handling and Storage of Air Bag System Components1040
Precautions on Disposal of Air Bag and Seat Belt Pretensioner1043
General Description1043
Air Bag System Construction1043
Air Bag System Input / Output Table1044
Schematic and Routing Diagram1045
Air Bag System Wiring Circuit Diagram1045
Component Location1047
Air Bag System Components, Wiring and Connectors Location1047
Diagnostic Information and Procedures1048
Air Bag Diagnostic System Check1048
Air Bag Diagnostic System Check Flow1048
DTC Table1049
DTC Check1050
DTC Clearance1050
Scan Tool Data1051
“AIR BAG” Warning Right Comes ON Steady1051
“AIR BAG” Warning Right Does Not Come ON1053
“AIR BAG” Warning Right Flashes1054
DTC B1013: SDM fault1055
DTC B1014: “AIR BAG” Warning Right Circuit Failure1055
DTC B1016: Power Source Voltage High1056
DTC B1017: Power Source Voltage Low1058
DTC B1021: Front Air Bag Module Deployed1060
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed1060
DTC B1026: Pretensioner Activated1061
DTC B1027: Reusable Number Exceeded1062
DTC B1031: Driver Air Bag Initiator Circuit Resistance High1062
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low1067
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground1072
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit1077
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High1082
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low1085
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground1088
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit1091
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High1094
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low1096
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground1098
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit1100
DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High1102
DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low1105
DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground1108
DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit1111
DTC B1071: Forward-Sensor Performance Problem1114
DTC B1072: Forward-Sensor Communication Error1114
DTC B1073: Forward-Sensor Circuit Short to Ground1114
DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open1116
DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem1118
DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error1118
DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground1118
DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open1119
DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID1121
DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High1122
DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low1124
DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground1126
DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit1128
Contact Coil Cable and Its Circuit Check1131
Inspection of Intermittent and Poor Connections1133
Repair and Inspection Required after Accident1134
Repair Instructions1136
Disabling Air Bag System1136
Enabling Air Bag System1137
SDM Removal and Installation1138
SDM Inspection1139
Driver Air Bag (Inflator) Module Removal and Installation1139
Driver Air Bag (Inflator) Module Inspection1141
Passenger Air Bag (Inflator) Module Removal and Installation1141
Passenger Air Bag (Inflator) Module Inspection1143
Side-Air Bag (Inflator) Module Removal and Installation1143
Side-Air Bag (Inflator) Inspection1145
Side Curtain-Air Bag (Inflator) Module Removal and Installation1145
Side Curtain-Air Bag (Inflator) Module Inspection1147
Forward-Sensor Removal and Installation1147
Forward-Sensor Inspection1148
Side-Sensor Removal and Installation1148
Side-Sensor Inspection1149
Passenger Air Bag (Inflator) Module Repair Harness Installation1150
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal1151
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal1162
Specifications1163
Tightening Torque Specifications1163
Special Tools and Equipment1163
Use of Special Tools1163
Recommended Service Material1165
Special Tool1165
Body, Cab and Accessories1167
Precautions1171
Precautions1171
Precautions on Body, Cab and Accessories1171
Precautions for Body Service1171
Fastener Caution for Body Service1171
Wiring Systems1172
Precautions1172
Cautions in Body Electrical System Servicing1172
General Description1172
Abbreviations1172
Wire / Connector Color Symbols1172
Symbols and Marks1173
How to Read Connector Layout Diagram1175
How to Read Connector Codes and Terminal Nos1176
How to Read Ground Point1178
How to Read Power Supply Diagram1179
How to Read System Circuit Diagram1179
Connector Layout Diagram1181
Connector Layout Diagram1181
Engine Compartment1181
Instrument Panel1187
Door, Roof1191
Floor1194
Rear1200
Ground Point1201
Ground (earth) Point1201
Power Supply Diagram1202
Power Supply Diagram1202
Fuses and the Protected Parts1204
Fuses in Main Fuse Box (RHD)1204
Fuses in Main Fuse Box (LHD)1204
Individual Circuit Fuse Box No 11205
Individual Circuit Fuse Box No 2 (In J/B)1206
Junction Block (J/B) Connector / Fuse Layout1208
Junction Block Inner Circuit (Overview)1209
Junction Block Inner Circuit (Detail)1211
System Circuit Diagram1216
System Circuit Diagram1216
A-1 Cranking System Circuit Diagram1217
A-2 Charging System Circuit Diagram1218
A-3 Ignition System Circuit Diagram1219
A-4 Cooling System Circuit Diagram1220
A-5 Engine and A/C Control System Circuit Diagram1221
A-6 A/T Control System Circuit Diagram1226
A-7 Immobilizer System Circuit Diagram1228
A-8 Body Control System Circuit Diagram1229
B-1 Windshield Wiper and Washer Circuit Diagram1233
B-2 Rear Wiper and Washer Circuit Diagram1234
B-3 Rear Defogger Circuit Diagram1235
B-4 Power Window Circuit Diagram1236
B-5 Power Door Lock Circuit Diagram1238
B-6 Power Mirror Circuit Diagram1240
B-7 Horn Circuit Diagram1241
B-8 Seat Heater Circuit Diagram1242
B-9 Keyless Start System Circuit Diagram1243
C-1 Combination Meter Circuit Diagram (Meter)1244
C-2 Combination Meter Circuit Diagram (Indicator)1245
C-3 Combination Meter Circuit Diagram (Warning Light)1246
D-1 Headlight System Circuit Diagram1248
D-2 Position, Tail and Licence Plate Light System Circuit Diagram1250
D-3 Front Fog Light System Circuit Diagram1251
D-4 Illumination Light System Circuit Diagram1252
D-5 Interior Light System Circuit Diagram1253
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram1254
D-7 Brake Light System Circuit Diagram1256
D-8 Back-Up Light System Circuit Diagram1257
D-9 Headlight Beam Leveling System Circuit Diagram1258
D-10 Rear Fog Light Circuit Diagram1259
E-1 Heater System Circuit Diagram1260
E-2 Auto A/C System Circuit Diagram1262
F-1 Air-Bag System Circuit Diagram1264
F-2 Anti-Lock Brake System Circuit Diagram1266
F-3 Electronic Stability Program System Circuit Diagram1268
F-4 Power Steering System Circuit Diagram1270
G-1 Audio System Circuit Diagram1272
G-2 Multi Information Display / Accessory Socket System Circuit Diagram1273
List of Connector1274
List of Connectors1274
C Connector1274
D Connector (M16A engine)1275
E Connector1275
G Connector1277
J Connector1279
K Connector1280
L Connector1280
M Connector (SPORT model)1282
O Connector1282
R Connector1282
Lighting Systems1283
Component Location1283
Lighting System Components Location1283
Interior Light System Location1284
Diagnostic Information and Procedures1284
Headlight Symptom Diagnosis1284
Headlight Leveling System Symptom Diagnosis (If Equipped)1284
Turn Signal and Hazard Warning Light Symptom Diagnosis1285
Clearance, Tail and License Plate Light Symptom Diagnosis1285
Back-Up Light Symptom Diagnosis1286
Brake Light Symptom Diagnosis1286
Front Fog Light Symptom Diagnosis (If Equipped)1286
Interior Light Symptom Diagnosis1287
Repair Instructions1287
Headlight Housing Removal and Installation1287
Headlight Bulb Replacement1288
Headlight Aiming Adjustment with Screen1288
Headlight Switch (in Lighting Switch) Removal and Installation1290
Headlight Switch (in Lighting Switch) Inspection1290
Hazard Warning Switch Removal and Installation1290
Hazard Warning Switch Inspection1291
Brake Light Switch Inspection1291
Turn Signal Light Switch (in Lighting Switch) Removal and Installation1291
Turn Signal Light Switch (in Lighting Switch) Inspection1291
Turn Signal and Hazard Warning Relay Removal and Installation1291
Turn Signal and Hazard Warning Relay Inspection1292
License Light Removal and Installation1292
Front Fog Light Removal and Installation (If Equipped)1293
Front Fog Light Bulb Replacement (If Equipped)1293
Front Fog Light Switch Inspection (If Equipped)1293
Front Fog Light Relay Inspection (If Equipped)1293
Front Fog Light Aiming Adjustment with Screen (If Equipped)1294
Headlight Leveling Switch Inspection (If Equipped)1295
Headlight Leveling Actuator Inspection (If Equipped)1295
Instrumentation / Driver Info / Horn1296
Precautions1296
Precautions in Diagnosing Troubles for Combination Meter1296
General Description1296
CAN Communication System Description1296
Auto Volume Control System Description (If Equipped)1298
Schematic and Routing Diagram1299
Combination Meter Circuit Diagram1299
Component Location1301
Audio System Component Location1301
Diagnostic Information and Procedures1301
Speedometer and VSS Symptom Diagnosis1301
Tachometer Symptom Diagnosis1301
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis1302
Fuel Meter Symptom Diagnosis1302
Low Fuel Warning Light Symptom Diagnosis1302
Oil Pressure Warning Light Symptom Diagnosis1303
Brake and Parking Brake Warning Light Symptom Diagnosis1303
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)1303
A/T Shift Position Indicator Symptom Diagnosis (A/T Model)1304
Charge Warning Light Symptom Diagnosis1304
Main Beam (High Beam) Indicator Symptom Diagnosis1304
Warning Buzzer Circuit Symptom Diagnosis1305
Cigarette Lighter Symptom Diagnosis (If Equipped)1305
Horn Symptom Diagnosis1305
Information Display Symptom Diagnosis (If Equipped)1306
Clock Symptom Diagnosis (If Equipped)1307
Audio System Symptom Diagnosis (If Equipped)1307
Remote Audio Control Switch Symptom Diagnosis (If Equipped)1308
Navigation Symptom Diagnosis (If Equipped)1309
Repair Instructions1309
Ignition Switch Removal and Installation1309
Ignition Switch Inspection1309
Combination Meter Removal and Installation1310
Fuel Level Sensor Removal and Installation1310
Fuel Level Sensor Inspection1310
Oil Pressure Switch Removal and Installation1310
Oil Pressure Switch Inspection1311
Engine Coolant Temperature (ECT) Sensor Inspection1311
Brake Fluid Level Switch Inspection1311
Parking Brake Switch Inspection1311
Door Switch (Front / Rear Door) Inspection1312
Rear End Door Switch Inspection1312
Outside Air Temperature Sensor Removal and Installation (If Equipped)1312
Outside Air Temperature Sensor Inspection (If Equipped)1312
Instrument Panel Removal and Installation1313
Information Display (Clock) Removal and Installation1314
Audio Unit Removal and Installation1314
Front Speaker Removal and Installation1314
Rear Speaker Removal and Installation1315
Horn Removal and Installation1315
Horn Inspection1315
Horn Relay Inspection1315
Antenna Amplifier Removal and Installation1316
Remote Audio Control Switch Removal and Installation (If Equipped)1316
Remote Audio Control Switch Inspection (If Equipped)1317
Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)1317
Specifications1317
Tightening Torque Specifications1317
Wipers / Washers1318
Diagnostic Information and Procedures1318
Front Wiper and Washer Symptom Diagnosis1318
Rear Wiper and Washer Symptom Diagnosis1318
Repair Instructions1319
Wipers and Washers Components1319
Washer Tank and Washer Pump Removal and Installation1320
Washer Pump Inspection1320
Windshield Wiper Removal and Installation1321
Windshield Wiper Motor Inspection1322
Rear Wiper Removal and Installation1323
Rear Wiper Motor Inspection1324
Windshield Wiper and Washer Switch Removal and Installation1324
Windshield Wiper and Washer Switch Inspection1325
Rear Wiper and Washer Switch Removal and Installation1326
Rear Wiper and Washer Switch Inspection1326
Rear Wiper Relay Removal and Installation1327
Rear Wiper Relay Inspection1327
Specifications1327
Tightening Torque Specifications1327
Glass / Windows / Mirrors1328
General Description1328
Rear End Door Window Defogger System Description1328
Windshield Construction1328
Diagnostic Information and Procedures1329
Rear End door Window Defogger Symptom Diagnosis1329
Power Window Control System Symptom Diagnosis1329
Power Door Mirror Control System Symptom Diagnosis1330
Door Mirror Heater Symptom Diagnosis (If Equipped)1330
Repair Instructions1331
Windshield Removal and Installation1331
Front Door Window Components1335
Front Door Glass Removal and Installation1335
Front Door Window Regulator Removal and Installation1336
Front Door Window Regulator Inspection1337
Rear Door Window Components1337
Rear Door Glass Removal and Installation1338
Rear Door Window Regulator Removal and Installation1339
Rear Door Window Regulator Inspection1339
Rear End Door Window Components1340
Rear End Door Glass Removal and Installation1340
Rear End Door Window Defogger Switch Inspection1341
Rear End Door Window Defogger Relay Inspection1341
Rear End Door Window Defogger Wire Inspection1342
Rear End Door Window Defogger Wire Repair1342
Power Window Main Switch Inspection1343
Power Window Sub Switch Inspection1344
Door Mirror Components1345
Door Mirror Removal and Installation1345
Power Door Mirror Switch Inspection1345
Power Door Mirror Actuator Inspection1346
Door Mirror Heater Switch Inspection (If Equipped)1346
Door Mirror Heater Inspection (If Equipped)1346
Special Tools and Equipment1346
Recommended Service Material1346
Security and Locks1347
General Description1347
Key Coding Construction1347
Rear End Door Opener System Description1347
Component Location1348
Power Door Lock and Keyless Entry System Component Location1348
Diagnostic Information and Procedures1349
Power Door Lock System Symptom Diagnosis1349
Power Door Lock System Operation Inspection1349
Keyless Entry System Symptom Diagnosis (If Equipped)1350
Keyless Entry System Operation Inspection1351
Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)1351
Rear End Door Opener System Symptom Diagnosis1351
Rear End Door Opener System Operation Inspection1351
Repair Instructions1352
Front Door Lock Assembly Components1352
Front Door Lock Assembly Removal and Installation1352
Front Door Lock Assembly Inspection1354
Power Door Lock Switch Inspection1354
Door Key Cylinder Switch Inspection1354
Power Door Lock Actuator Inspection1355
Rear Door Lock Assembly Components1356
Rear Door Lock Assembly Removal and Installation1356
Rear Door Lock Assembly Inspection1356
Rear End Door Lock Assembly Components1357
Rear End Door Lock Assembly Removal and Installation1357
Rear End Door Lock Assembly Inspection1358
Rear End Door Opener Switch Inspection1358
Replacement of Transmitter Battery1359
Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System)1359
Keyless Entry Answer Back Function Change- over Procedure (If Equipped)1360
Keyless Entry Receiver Removal and Installation1360
Keyless Entry Receiver and Its Circuit Inspection1361
Specifications1362
Tightening Torque Specifications1362
Special Tools and Equipment1362
Recommended Service Material1362
Seats1363
Repair Instructions1363
Front Seat Components1363
Front Seat Removal and Installation1364
Rear Seat Components1365
Rear Seat Removal and Installation1366
Specifications1366
Tightening Torque Specifications1366
Special Tools and Equipment1366
Recommended Service Material1366
Interior Trim1367
Repair Instructions1367
Floor Carpet Removal and Installation1367
Head Lining Removal and Installation1367
Console Box Components1368
Specifications1369
Tightening Torque Specifications1369
Hood / Fenders / Doors1370
Repair Instructions1370
Hood Removal and Installation1370
Hood Inspection and Adjustment1370
Front Fender Components1371
Front Fender Removal and Installation1371
Front Door Assembly Components1372
Front Door Assembly Removal and Installation1372
Rear Door Assembly Components1374
Rear Door Assembly Removal and Installation1374
Rear End Door Assembly Components1375
Rear End Door Assembly Removal and Installation1375
Specifications1377
Tightening Torque Specifications1377
Special Tools and Equipment1377
Recommended Service Material1377
Body Structure1378
Repair Instructions1378
Front Bumper and Rear Bumper Components1378
Cowl Top Components1379
Specifications1380
Body Dimensions1380
Panel Clearance1387
Paint / Coatings1388
General Description1388
Anti-Corrosion Treatment Construction1388
Plastic Parts Finishing1389
Component Location1390
Sealant Application Areas1390
Under Coating Application Areas1395
Anti-Corrosion Compound Application Area1397
Exterior Trim1398
Repair Instructions1398
Roof Molding Components1398
Splash Guard (If Equipped) Components1399
Control Systems1401
Precautions1403
Precautions1403
Precautions for Control Systems1403
Body Electrical Control System1404
Precautions1404
Precautions in Diagnosing Trouble1404
General Description1404
BCM General Description1404
CAN Communication System Description1405
Theft Deterrent Light1406
Security Alarm Description (If Equipped)1406
Schematic and Routing Diagram1407
Body Electrical Control System Wiring Circuit Diagram1407
Connector Layout Diagram of BCM and Junction Block Assembly1410
Component Location1411
BCM and Related System Component Location1411
Diagnostic Information and Procedures1412
BCM Self-Diagnosis Function1412
Body Electrical Control System Check1413
Scan Tool Data1415
DTC Table1417
DTC Check1417
DTC Clearance1418
BCM Power Circuit and Ground Circuit Check1419
DTC B1133 (DTC No 1133): Battery Voltage Too High1420
DTC B1141 / DTC B1142 (No 1141 / No 1142): Outside Air Temperature (Ambient Temp) Sensor Circuit Malfunction1421
DTC B1150 (No 1150): Air Bag Communication Circuit Malfunction1422
DTC B1157 (No 1157): Air Bag Deployment Signal Input1423
DTC B1170 (No 1170): EEPROM Access Error1424
DTC U0155 (No 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module1424
DTC U1073 (No 1073): Control Module Communication Bus Off1427
DTC U1100 (No 1100): Lost Communication with ECM1428
DTC U1101 (No 1101): Lost Communication with TCM1430
DTC U1144 (No 1144): Lost Communication with Keyless Start Control Module1432
Inspection of BCM and its Circuits1434
Repair Instructions1442
BCM (Included in Junction Block Assembly) Removal and Installation1442
Outside Air Temperature Sensor Removal and Installation1442
Outside Air Temperature Sensor Inspection1442
Security Alarm Mode Selection Procedure (If Equipped)1442
Special Tools and Equipment1443
Special Tool1443
Immobilizer Control System1444
Precautions1444
Precautions in Diagnosing Troubles1444
Precaution in Replacing ECM1444
Precautions in Handling Immobilizer Control System1444
General Description1445
Immobilizer Control System Introduction1445
Immobilizer Control System Components Location1446
On-Board Diagnostic System Description (Self-diagnosis Function)1446
Schematic and Routing Diagram1447
Immobilizer Control System Wiring Circuit Diagram1447
Diagnostic Information and Procedures1448
Immobilizer Control System Check1448
Diagnostic Trouble Code (DTC) Check1448
Diagnostic Trouble Code (DTC) Clearance1449
Diagnostic Trouble Code (DTC) Table1449
Scan Tool Data1450
Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop1450
Immobilizer Indicator Lamp Remains ON after Engine Starts1451
DTC P1614: Transponder Response Error1452
DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only)1452
DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only)1453
DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)1454
DTC P1621: Immobilizer Communication Line Error1455
DTC P1622: EEPROM Reading / Writing Error1456
DTC P1623: Unregistered Transponder1456
DTC P1625: Immobilizer Antenna Error1457
DTC P1636: Immobilizer Information Registration Failure1457
DTC P1638: Immobilizer Information Mismatched1458
Inspection of Immobilizer Control Module (ICM) and Its Circuit1459
Repair Instructions1461
Immobilizer Control Module (ICM) Removal and Installation1461
Registration of the Ignition Key1461
Procedure after ECM Replacement1461
Special Tools and Equipment1462
Special Tool1462
Keyless Start System1463
General Description1463
Keyless Start System Description1463
Parts and Functions1464
Keyless Engine Start Function1465
Door Lock Function of Keyless Start System1466
Operation Area of Remote Controller1467
Alarm Function1468
CAN Communication System Description1468
Schematic and Routing Diagram1469
Keyless Start System Electric Wiring Circuit Diagram1469
Diagnostic Information and Procedures1470
Precautions in Diagnosing Troubles1470
Self-Diagnosis Function1470
Keyless Start System Diagnosis Introduction1470
Keyless Start System Check1470
Customer Questionnaire (Example)1471
Key Indicator Lamp Check1472
DTC Check1472
DTC Table1473
DTC Clearance1474
Keyless Start System Symptom Diagnosis1474
Keyless Start System Operation Inspection1475
Door Lock Operation (Keyless Start System)1476
Inspection of Keyless Start Control Module and Its Circuits1476
No DTC Detection After Performing DTC Check1480
Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed)1482
Keyless Start Control Module Power and Ground Circuit Check1484
DTC No 11: Communication Error with Steering Lock Unit1485
DTC No 13 / No 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction1486
DTC No 21 / No 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)1486
DTC No 31: Lost Communication with BCM1487
DTC No 33: Control Module Communication Bus Off1489
DTC No 51 / No 52 / No 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure1490
Repair Instructions1492
Antennas and Request Switches Removal and Installation1492
Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection1493
Steering Lock Unit Removal and Installation1493
Steering Lock Unit Inspection1493
Front Door Lock Switch Inspection1493
Keyless Start Control Module Removal and Installation1494
Remote Controller Inspection1494
Replacement of Remote Controller Battery1494
Registration Procedure for Remote Controller ID Code1495
VIDEO PREVIEW OF THE MANUAL:
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S.M