Suzuki SX4, SX4 Crossover Repair Service Manual 2006-2016
Complete service repair manual with Electrical Wiring Diagrams for 2006-2016 Suzuki SX4, SX4 Crossover , with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki SX4, SX4 Crossover workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Suzuki
YEAR: 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
MODEL: SX4/SX4 Crossover (RW415, RW416, RW420 Series)
FORMAT: PDF
LANGUAGE: EN/DE/FR/ES/HU/IT/NL/SK
PRODUCT DETAILS:
Total Pages: 3,442 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: EN/DE/FR/ES/HU/IT/NL/SK
TABLE OF CONTENTS
IMPORTANT...1
FOREWORD...3
TABLE OF CONTENTS...5
Precautions...7
Precautions...8
Precautions...8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System...8
General Precautions...11
Warning for Wheel (with tire) Removal...13
Precautions in Servicing 4WD Model...14
Precautions for Catalytic Converter...14
Precautions for Installing Mobile Communication Equipment...15
Precaution for CAN Communication System...15
Precautions for Electrical Circuit Service...15
Air Bag Warning...17
Air Bag System Service Warning...17
Fastener Caution...18
Suspension Caution...18
Wheels and Tires Caution...18
ABS Caution...18
Precaution for Vehicle Equipped with ESP‚ System...18
Brake Caution...18
Repair Instructions...19
Electrical Circuit Inspection Procedure...19
Intermittent and Poor Connection Inspection...21
General Information...23
General Information...24
General Description...24
Abbreviations...24
Symbols...25
Wire Color Symbols...25
Fasteners Information...26
Vehicle Lifting Points...28
Vehicle Identification Number...29
Engine Identification Number...29
Transmission Identification Number...29
Component Location...30
Warning, Caution and Information Labels Location...30
Maintenance and Lubrication...32
Precautions...32
Precautions for Maintenance and Lubrication...32
Scheduled Maintenance...32
Maintenance Schedule under Normal Driving Conditions...32
Maintenance Recommended under Severe Driving Conditions...33
Repair Instructions...34
Accessory Drive Belt Inspection...34
Accessory Drive Belt Replacement...35
Valve Lash (Clearance) Inspection...35
Engine Oil and Filter Change...35
Engine Coolant Change...36
Exhaust System Inspection...37
Spark Plug Replacement...37
Air Cleaner Filter Inspection...37
Air Cleaner Filter Replacement...37
Fuel Lines and Connections Inspection...37
Fuel Filter Replacement...37
Fuel Tank Inspection...38
PCV Valve Inspection...38
Fuel Evaporative Emission Control System Inspection...38
Brake Discs and Pads (Front) Inspection...38
Brake Drums and Shoes (Rear) Inspection...38
Brake Hoses and Pipes Inspection...39
Brake Fluid Replacement...39
Brake Lever and Cable Inspection...39
Clutch Pedal Inspection...39
Clutch Fluid Inspection...39
Tires Inspection...40
Wheel Discs Inspection...40
Wheel Bearing Inspection...40
Suspension System Inspection...40
Steering System Inspection...40
Drive Shaft (Axle) Boots Inspection...41
Propeller Shaft (4WD) Inspection...41
Manual Transaxle Oil Inspection...41
Manual Transaxle Oil Replacement...41
Automatic Transaxle Fluid Level Inspection...41
Automatic Transaxle Fluid Replacement...41
Automatic Transaxle Fluid Cooler Hose Inspection...41
Transfer Oil Inspection (4WD)...42
Transfer Oil Replacement (4WD)...42
Rear Deferential Oil Inspection (4WD)...42
Rear Deferential Oil Replacement (4WD)...42
All Latches, Hinges and Locks Inspection...42
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...44
Recommended Fluids and Lubricants...44
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 for DTC Troubleshooting...52
Precautions of ECM Circuit Inspection...52
Precautions of Electric Throttle Body System Calibration...52
Precaution on CAN Troubleshooting...53
General Description...55
Statement on Cleanliness and Care...55
Engine Diagnosis General Description...55
On-Board Diagnostic System Description...55
Data Link Connector (DLC) Description...58
Engine and Emission Control System Description...58
CAN Communication System Description...59
Air Intake System Description...61
Description of Electric Throttle Body System Calibration...61
Electric Throttle Body System Description...61
Electronic Control System Description...62
Engine and Emission Control Input / Output Table...63
Schematic and Routing Diagram...64
ECM Input / Output Circuit Diagram...64
Engine and Emission Control System Flow Diagram...68
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...75
DTC Clearance...76
Troubleshooting for Communication Error with Scan Tool Using CAN...76
DTC Table...82
Fail-Safe Table...86
Scan Tool Data...88
Visual Inspection...93
Engine Basic Inspection...93
Engine Symptom Diagnosis...95
Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)...102
Malfunction Indicator Lamp Remains ON after Engine Starts...104
DTC P0010: Camshaft Position Actuator Circuit (for engine with VVT system)...105
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / Retarded (for engine with VVT system)...107
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)...109
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)...111
DTC P0101: Mass Air Flow Circuit Range / Performance...113
DTC P0102: Mass Air Flow Circuit Low Input...116
DTC P0103: Mass Air Flow Circuit High Input...117
DTC P0106: Manifold Absolute Pressure Range / Performance...119
DTC P0107: Manifold Absolute Pressure Circuit Low Input...120
DTC P0108: Manifold Absolute Pressure Circuit High Input...122
DTC P0111: Intake Air Temperature Circuit Range / Performance...124
DTC P0112: Intake Air Temperature Sensor Circuit Low...126
DTC P0113: Intake Air Temperature Sensor Circuit High...128
DTC P0116: Engine Coolant Temperature Circuit Range / Performance...130
DTC P0117: Engine Coolant Temperature Circuit Low...133
DTC P0118: Engine Coolant Temperature Circuit High...134
DTC P0122: Throttle Position Sensor (Main) Circuit Low...137
DTC P0123: Throttle Position Sensor (Main) Circuit High...139
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)...142
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)...145
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)...146
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)...148
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)...151
DTC P0171 / P0172: Fuel System Too Lean / Rich...153
DTC P0222: Throttle Position Sensor (Sub) Circuit Low...155
DTC P0223: Throttle Position Sensor (Sub) Circuit High...157
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...160
DTC P0327 / P0328: Knock Sensor Circuit Low / High...162
DTC P0335: Crankshaft Position (CKP) Sensor Circuit...164
DTC P0340: Camshaft Position (CMP) Sensor Circuit...166
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected...169
DTC P0403: Exhaust Gas Recirculation Control Circuit...172
DTC P0420: Catalyst System Efficiency below Threshold...174
DTC P0443: Evaporative Emission System Purge Control Valve Circuit...176
DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High...178
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...179
DTC P0481: Cooling Fan 2 (A/C Condenser Fan) Control Circuit...181
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction...184
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low...186
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...188
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance...189
DTC P0616: Starter Relay Circuit Low...190
DTC P0617: Starter Relay Circuit High...191
DTC P1510: ECM Back-Up Power Supply Malfunction...193
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance...194
DTC P2102: Throttle Actuator Control Motor Circuit Low...196
DTC P2103: Throttle Actuator Control Motor Circuit High...197
DTC P2111: Throttle Actuator Control System - Stuck Open...198
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance...199
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input...201
DTC P2123: Pedal Position Sensor (Main) Circuit High Input...203
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input...205
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input...208
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation...210
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation...213
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction...215
DTC U0073: Control Module Communication Bus Off...216
DTC U0101: Lost Communication with TCM...216
DTC U0121: Lost Communication with ABS Control Module...216
DTC U0140: Lost Communication with Body Control Module...216
Troubleshooting for CAN-DTC...217
Inspection of ECM and Its Circuits...222
ECM Power and Ground Circuit Check...244
Fuel Injector Circuit Check...247
Fuel Pump and Its Circuit Check...249
Fuel Pressure Check...252
A/C Condenser Cooling Fan Control System Inspection...253
A/C System Circuits Check...256
Electric Load Signal Circuit Check...260
Radiator Cooling Fan Control System Check...262
Repair Instructions...263
Idle Speed and IAC Throttle Valve Opening Inspection...263
Special Tools and Equipment...264
Special Tool...264
Aux. Emission Control Devices...265
Diagnostic Information and Procedures...265
EGR System Inspection (If Equipped)...265
Repair Instructions...265
EVAP Canister Purge Inspection...265
EVAP Canister Purge Valve and Its Circuit Inspection...265
Vacuum Passage Inspection...266
Vacuum Hose Inspection...267
EVAP Canister Purge Valve Inspection...267
EVAP Canister Inspection...268
EGR Valve Removal and Installation (If Equipped)...268
EGR Valve Inspection (If Equipped)...268
PCV Hose Inspection...269
PCV Valve Inspection...269
Special Tools and Equipment...269
Special Tool...269
Engine Electrical Devices...270
Repair Instructions...270
Engine Control Module (ECM) Removal and Installation...270
Manifold Absolute Pressure (MAP) Sensor Inspection (If Equipped)...271
Electric Throttle Body Assembly On-Vehicle Inspection...271
Electric Throttle Body System Calibration...273
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection...274
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation...274
Accelerator Pedal Position (APP) Sensor Assembly Inspection...274
Engine Coolant Temperature (ECT) Sensor Removal and Installation...275
Engine Coolant Temperature (ECT) Sensor Inspection...276
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection (If Equipped)...276
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation (If Equipped)...276
Camshaft Position (CMP) Sensor Removal and Installation...277
Camshaft Position (CMP) Sensor Inspection...278
Crankshaft Position (CKP) Sensor Removal and Installation...278
Crankshaft Position (CKP) Sensor Inspection...279
Knock Sensor Removal and Installation...279
Main Relay, Fuel Pump Relay, Starting Motor Control Relay, Throttle Actuator Control Relay and Radiator Cooling Fan Relay Inspection...280
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection...280
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation...281
Intake Air Temperature (IAT) Sensor Inspection...281
Specifications...282
Tightening Torque Specifications...282
Engine Mechanical...283
General Description...283
Engine Construction Description...283
Camshaft Position Control (VVT Variable Valve Timing) System Description...285
Diagnostic Information and Procedures...287
Compression Check...287
Engine Vacuum Check...288
Valve Lash (Clearance) Inspection...289
Repair Instructions...292
Air Intake System Components...292
Air Cleaner Filter Removal and Installation...292
Air Cleaner Filter Inspection and Cleaning...292
Air Cleaner Assembly Removal and Installation...293
Cylinder Head Cover Removal and Installation...293
Throttle Body and Intake Manifold Components...295
Throttle Body On-Vehicle Inspection...296
Electric Throttle Body Assembly Removal and Installation...296
Throttle Body Cleaning...296
Intake Manifold Removal and Installation...297
Engine Mountings Components...298
Engine Assembly Removal and Installation...299
Timing Chain Cover Components...304
Timing Chain Cover Removal and Installation...305
Timing Chain Cover Inspection...307
Oil Control Valve Removal and Installation (For Engine with VVT)...308
Oil Control Valve Inspection (For Engine with VVT)...308
Timing Chain and Chain Tensioner Components...309
Timing Chain and Chain Tensioner Removal and Installation...309
Timing Chain and Chain Tensioner Inspection...313
Camshaft, Tappet and Shim Components...314
Camshaft, Tappet and Shim Removal and Installation...315
Camshaft, Tappet and Shim Inspection...318
Valves and Cylinder Head Components...321
Valves and Cylinder Head Removal and Installation...322
Valves and Cylinder Head Disassembly and Assembly...324
Valves and Valve Guides Inspection...327
Cylinder Head Inspection...329
Valve Spring Inspection...330
Pistons, Piston Rings, Connecting Rods and Cylinders Components...330
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation...331
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly...332
Cylinders, Pistons and Piston Rings Inspection...333
Piston Pins and Connecting Rods Inspection...335
Crank Pin and Connecting Rod Bearings Inspection...337
Main Bearings, Crankshaft and Cylinder Block Components...340
Main Bearings, Crankshaft and Cylinder Block Removal and Installation...341
Crankshaft Inspection...344
Main Bearings Inspection...346
Sensor Plate Inspection...350
Rear Oil Seal Inspection...350
Flywheel Inspection...350
Cylinder Block Inspection...350
Specifications...351
Tightening Torque Specifications...351
Special Tools and Equipment...352
Recommended Service Material...352
Special Tool...352
Engine Lubrication System...354
General Description...354
Engine Lubrication Description...354
Diagnostic Information and Procedures...355
Oil Pressure Check...355
Repair Instructions...356
Oil Pan and Oil Pump Strainer Components...356
Oil Pan and Oil Pump Strainer Removal and Installation...357
Oil Pan and Oil Pump Strainer Cleaning...358
Oil Pump Components...359
Oil Pump Removal and Installation...359
Oil Pump Disassembly and Reassembly...359
Oil Pump Inspection...360
Specifications...362
Tightening Torque Specifications...362
Special Tools and Equipment...362
Recommended Service Material...362
Special Tool...362
Engine Cooling System...363
General Description...363
Cooling System Description...363
Coolant Description...363
Schematic and Routing Diagram...364
Coolant Circulation...364
Diagnostic Information and Procedures...365
Engine Cooling Symptom Diagnosis...365
Repair Instructions...366
Cooling System Components...366
Coolant Level Check...367
Engine Cooling System Inspection and Cleaning...367
Cooling System Draining...367
Cooling System Flush and Refill...368
Cooling Water Pipes or Hoses Removal and Installation...368
Thermostat Removal and Installation...369
Thermostat Inspection...369
Radiator Cooling Fan Assembly On-Vehicle Inspection...370
Radiator Cooling Fan Relay Inspection...370
Radiator Cooling Fan Assembly Removal and Installation...370
Radiator Cooling Fan Disassembly and Reassembly...371
Radiator On-Vehicle Inspection and Cleaning...371
Radiator Removal and Installation...371
Water Pump / Generator Drive Belt Tension Inspection and Adjustment...372
Water Pump / Generator Drive Belt Removal and Installation...372
Water Pump Removal and Installation...373
Water Pump Inspection...374
Specifications...374
Tightening Torque Specifications...374
Special Tools and Equipment...374
Recommended Service Material...374
Fuel System...375
Precautions...375
Precautions on Fuel System Service...375
General Description...376
Fuel System Description...376
Fuel Delivery System Description...376
Fuel Pump Description...376
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...381
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...386
Fuel Tank Inlet Valve Removal and Installation...386
Fuel Tank Inlet Valve Inspection...386
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...413
Battery Inspection...413
Generator Symptom Diagnosis...414
Generator Test (Undercharged Battery Check)...414
Generator Test (Overcharged Battery Check)...415
Repair Instructions...416
Jump Starting in Case of Emergency...416
Battery Dismounting and Remounting...416
Water Pump / Generator Drive Belt Tension Inspection and Adjustment...417
Water Pump / Generator Drive Belt Removal and Installation...418
Generator Dismounting and Remounting...418
Generator Components...419
Generator Inspection...420
Specifications...422
Charging System Specifications...422
Tightening Torque Specifications...422
Exhaust System...423
General Description...423
Exhaust System Description...423
Diagnostic Information and Procedures...423
Exhaust System Check...423
Repair Instructions...424
Exhaust System Components...424
Exhaust Manifold Removal and Installation...425
Exhaust Pipe and Muffler Removal and Installation...426
Specifications...426
Tightening Torque Specifications...426
Suspension...427
Precautions...429
Precautions...429
Precautions on Suspension...429
Suspension General Diagnosis...430
Diagnostic Information and Procedures...430
Suspension, Wheels and Tires Symptom Diagnosis...430
Front Suspension...432
General Description...432
Front Suspension Construction...432
Front Wheel Alignment Construction...433
Repair Instructions...433
Front Wheel Alignment Inspection and Adjustment...433
Camber and Caster Check...434
Steering Angle Check and Adjustment...435
Front Strut Assembly Components...435
Front Strut Assembly Removal and Installation...436
Front Strut Assembly Disassembly and Reassembly...437
Front Strut Assembly Check...438
Front Wheel Hub and Steering Knuckle Components...439
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation...439
Front Wheel Bearing and Wheel Hub Inspection...443
Suspension Control Arm Removal and Installation...444
Suspension Control Arm Bush Disassembly and Assembly...444
Suspension Control Arm / Steering Knuckle Check...445
Suspension Control Arm Bush Inspection...445
Suspension Control Arm Joint Check...445
Front Suspension Frame, Stabilizer Bar and/or Bush Components...446
Front Suspension Frame, Stabilizer Bar and/or Bush Removal and Installation...446
Front Suspension Frame Check...449
Front Stabilizer Bar, Bush and/or Joint Check...449
Front Suspension Fasteners Check...449
Specifications...450
Tightening Torque Specifications...450
Special Tools and Equipment...451
Recommended Service Material...451
Special Tool...451
Rear Suspension...452
Repair Instructions...452
Rear Suspension Components...452
Rear Wheel Alignment Inspection...453
Rear Shock Absorber Removal and Installation...453
Rear Shock Absorber Inspection...455
Rear Shock Absorber Bush Inspection...455
Rear Coil Spring Removal and Installation...455
Spring Upper Seat / Spring Lower Seat Inspection...457
Rear Axle Removal and Installation...457
Rear Axle and Coil Spring Inspection...458
Rear Axle Bush Inspection...458
Rear Wheel Hub Assembly Inspection...459
Rear Wheel Hub Assembly Removal and Installation...459
Specifications...461
Tightening Torque Specifications...461
Wheels and Tires...462
Precautions...462
Precautions in Wheels and Tires Servicing...462
General Description...462
Tires Description...462
Wheels Description...463
Irregular and/or Premature Wear Description...464
Wear Indicators Description...464
Radial Tire Waddle Description...464
Radial Tire Lead / Pull Description...465
Balancing Wheels Description...465
Repair Instructions...466
Wheel Discs Inspection...466
Wheel Balance Inspection and Adjustment...466
Tire Rotation...466
Wheel (with Tire) Removal and Installation...466
Tire Mounting and Dismounting...467
Tire Repair...467
Specifications...467
Wheels and Tires Specifications...467
Tightening Torque Specifications...467
Driveline / Axle...469
Precautions...471
Precautions...471
Precautions on Driveline / Axle...471
Drive Shaft / Axle...472
Front...472
General Description...472
Front Drive Shaft Construction...472
Component Location...472
Front Drive Shaft Assembly Components Location...472
Diagnostic Information and Procedures...473
Front Drive Shaft Symptom Diagnosis...473
Repair Instructions...473
Front Drive Shaft Components...473
Front Drive Shaft Assembly On-Vehicle Inspection...474
Front Drive Shaft Assembly Removal and Installation...474
Front Drive Shaft Disassembly and Reassembly...475
Center Shaft and Center Bearing Support Disassembly and Reassembly (If Equipped)...483
Specifications...484
Tightening Torque Specifications...484
Special Tools and Equipment...485
Recommended Service Material...485
Special Tool...485
Rear...486
General Description...486
Rear Drive Shaft Construction...486
Repair Instructions...486
Rear Drive Shaft Components...486
Rear Drive Shaft Assembly Removal and Installation...487
Rear Drive Shaft Disassembly and Reassembly...487
Specifications...489
Tightening Torque Specifications...489
Special Tools and Equipment...489
Recommended Service Material...489
Special Tool...489
Differential...490
Precautions...490
Precaution for Rear Differential Oil Leakage...490
Precautions in Diagnosing Trouble...490
General Description...491
Rear Differential Description...491
Coupling Description...491
4WD Control System Description...492
Function of 4WD Control System Component...492
Input / Output Signal Table of 4WD Control Module...493
On-Board Diagnostic System Description...493
CAN Communication System Description...494
Schematic and Routing Diagram...495
4WD Control System Wiring Circuit Diagram...495
Component Location...497
4WD Control System Components Location...497
Diagnostic Information and Procedures...498
4WD Control System Check...498
4WD Position Indicator Operation Check...500
4WD Control System Operation Inspection...500
Visual Inspection...501
DTC Check...501
DTC Clearance...501
DTC Table...502
Fail-Safe Table...502
Scan Tool Data...503
Rear Differential Symptom Diagnosis...504
4WD Control Symptom Diagnosis...504
4WD Position Indicator Does Not Come ON at Ignition Switch ON but Engine Stops...505
4WD Position Indicator Remains ON Steady at Ignition Switch ON...506
DTC C1240: 4WD Control Module Power Supply Circuit Malfunction...507
DTC C1243: Internal Circuit Malfunction of 4WD Control Module...508
DTC C1250: Coupling Air Temperature Sensor Circuit Open...508
DTC C1251: Coupling Air Temperature Sensor Circuit Short...510
DTC C1252: Coupling Assembly Circuit Open...511
DTC C1253: Coupling Assembly Circuit Short...513
DTC C1254: 2WD/4WD Switch Malfunction...514
DTC U0073: Control Module Communication Bus Off...516
DTC U0100: Lost Communication with ECM...516
DTC U0121: Lost Communication with ABS / ESP‚ Control Module...516
DTC U0155: Lost Communication with Instrument Panel Cluster (IPC) Control Module...516
Inspection of 4WD Control Module and Its Circuits...516
Repair Instructions...519
Rear Differential Oil Level Check...519
Rear Differential Oil Change...519
2WD/4WD Switch Removal and Installation...520
2WD/4WD Switch Inspection...520
4WD Control Module Removal and Installation...520
Coupling Air Temperature Sensor Removal and Installation...520
Coupling Air Temperature Sensor Inspection...521
Coupling Assembly Inspection...521
Rear Differential Mountings Components...522
Front Mounting Arm and/or Rear Mounting Bracket Assembly Removal and Installation...523
Rear Mounting Bracket Assembly Disassembly and Reassembly...523
Rear Differential Dismounting and Remounting...523
Rear Differential Components...524
Rear Differential Disassembly and Reassembly...525
Rear Differential Inspection...536
Specifications...537
Tightening Torque Specifications...537
Special Tools and Equipment...537
Recommended Service Material...537
Special Tool...538
Transfer...540
General Description...540
Transfer Description...540
Diagnostic Information and Procedures...540
Transfer Symptom Diagnosis...540
Repair Instructions...541
Transfer Oil Level Check...541
Transfer Oil Change...541
Transfer Dismounting and Remounting...542
Transfer Assembly Components...543
Transfer Assembly Disassembly and Reassembly...544
Reduction Drive Gear Assembly Disassembly and Reassembly...546
Reduction Driven Gear Assembly Disassembly and Reassembly...547
Transfer Right Case and Left Case Disassembly and Reassembly...548
Transfer Output Retainer Assembly Disassembly and Reassembly...549
Transfer Assembly Inspection...553
Bevel Gear Tooth Contact Inspection...553
Specifications...555
Tightening Torque Specifications...555
Special Tools and Equipment...556
Recommended Service Material...556
Special Tool...556
Propeller Shaft...558
Precautions...558
Propeller Shaft Caution...558
General Description...558
Propeller Shaft Construction...558
Diagnostic Information and Procedures...558
Propeller Shaft Symptom Diagnosis...558
Repair Instructions...559
Propeller Shaft Joint Check...559
Propeller Shaft Assembly Removal and Installation...559
Propeller Shaft Inspection...559
Specifications...560
Tightening Torque Specifications...560
Brakes...561
Precautions...564
Precautions...564
Precautions for Brakes...564
Brake Control System and Diagnosis...565
Precautions...565
Precautions on Brake...565
General Description...565
Brakes Construction...565
Brake Pedal Foot Protection System Construction (If Equipped)...566
Diagnostic Information and Procedures...566
Brakes Diagnosis Note...566
Brakes Symptom Diagnosis...567
Repair Instructions...569
Brake Pedal Components...569
Brake Pedal Free Height Inspection...569
Brake Pedal Play Inspection...569
Excessive Pedal Travel Inspection...570
Brake Fluid Level Inspection...570
Brake Light Switch Adjustment...571
Air Bleeding of Brake System...571
Front Brake Hose / Pipe Components...572
Front Brake Hose and Pipe Removal and Installation...573
Rear Brake Hose / Pipe Components...574
Rear Brake Hose and Pipe Removal and Installation...574
Brake Hose and Pipe Inspection...574
Master Cylinder and Brake Booster Components...575
Master Cylinder Reservoir Removal and Installation...576
Master Cylinder Removal and Installation...577
Master Cylinder Inspection...578
Booster Operation Inspection...578
Brake Booster Removal and Installation...580
Brake Booster Inspection...580
Booster Push Clevis Rod Adjustment...580
Specifications...581
Tightening Torque Specifications...581
Special Tools and Equipment...581
Recommended Service Material...581
Special Tool...581
Front Brakes...582
Repair Instructions...582
Front Disc Brake Components...582
Front Disc Brake Pad On-Vehicle Inspection...583
Front Disc Brake Pad Removal and Installation...583
Front Disc Brake Pad Inspection...584
Front Disc Brake Caliper Removal and Installation...584
Front Disc Brake Caliper Disassembly and Assembly...585
Front Disc Brake Caliper Check...587
Front Brake Disc Removal and Installation...587
Front Brake Disc Inspection...588
Specifications...589
Tightening Torque Specifications...589
Special Tools and Equipment...589
Recommended Service Material...589
Special Tool...589
Rear Brakes...590
Repair Instructions...590
Rear Drum Brake Components...590
Rear Brake Drum Removal and Installation...591
Rear Brake Drum and Shoe Inspection...591
Rear Brake Shoe On-Vehicle Inspection...592
Rear Brake Shoe Removal and Installation...592
Rear Brake Adjuster and Shoe Lever Check...593
Wheel Cylinder Removal and Installation...593
Wheel Cylinder Inspection...594
Brake Back Plate Removal and Installation...594
Specifications...595
Tightening Torque Specifications...595
Special Tools and Equipment...595
Recommended Service Material...595
Parking Brake...596
Repair Instructions...596
Parking Brake Cable Components...596
Parking Brake Inspection and Adjustment...597
Parking Brake Cable Removal and Installation...597
Parking Brake Lever Removal and Installation...598
Specifications...599
Tightening Torque Specifications...599
ABS...600
Precautions...600
Precautions in Diagnosing Troubles...600
Precautions in On-Vehicle Service...600
General Description...601
ABS Description...601
ABS Hydraulic Unit / Control Module Assembly Description...602
CAN Communication System Description...602
Schematic and Routing Diagram...603
ABS Schematic...603
ABS Wiring Circuit Diagram...604
Component Location...606
ABS Components Location...606
Diagnostic Information and Procedures...607
ABS Check...607
ABS Warning Light Check...609
EBD Warning Light (Brake Warning Light) Check...609
DTC Check...610
DTC Table...610
DTC Clearance...610
Scan Tool Data...611
ABS Warning Light Does Not Come ON at Ignition Switch ON...612
ABS Warning Light Comes ON Steady...614
EBD Warning Light (Brake Warning Light) Comes ON Steady...615
Serial Data Link Circuit Check...616
DTC C1013: Control Module Mismatch...619
DTC C1015: G Sensor Circuit (4WD Model)...620
DTC 1016: Brake Light Switch...621
DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder...622
DTC C1033: Wheel Speed Sensor Deviation...624
DTC C1041 / C1042 / C1045 / C1046 / C1051 / C1052 / C1055 / C1056: Inlet / Outlet Solenoid...625
DTC C1057: Power Supply Voltage Too High / Too Low...626
DTC C1061: Pump Motor Circuit...627
DTC C1063: Solenoid Valve Power Supply Driver Circuit...628
DTC C1071: Control Module Internal Defect...629
ABS Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check...629
Repair Instructions...630
ABS Hydraulic Unit Operation Check...630
ABS Hydraulic Unit / Control Module Assembly Components...631
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...632
ABS Hydraulic Unit / Control Module Assembly Removal and Installation...632
Front and Rear Wheel Speed Sensor On-Vehicle Inspection...633
Front Wheel Speed Sensor Removal and Installation...634
Front and Rear Wheel Speed Sensor Inspection...635
Rear Wheel Speed Sensor Removal and Installation (4WD Model)...635
Rear Wheel Speed Sensor Removal and Installation (2WD Model)...635
Front Wheel Speed Sensor Encoder On-Vehicle Inspection...636
Front Wheel Speed Sensor Encoder Removal and Installation...636
Rear Wheel Speed Sensor Encoder On-Vehicle Inspection...636
Rear Wheel Speed Sensor Encoder Removal and Installation...636
G Sensor Removal and Installation (4WD Model)...637
G Sensor Inspection (4WD Model)...637
Specifications...638
Tightening Torque Specifications...638
Special Tools and Equipment...638
Special Tool...638
Electronic Stability Program...639
Precautions...639
Precautions in Diagnosing Troubles...639
Precautions in On-Vehicle Service...639
Precautions in Hydraulic Unit Operation Check...639
Precautions in Sensor Calibration...639
Precautions in Speedometer Test or Other Tests...640
General Description...640
Electronic Stability Program System Description...640
Electronic Stability Program Construction...641
Components of Electronic Stability Program...641
On-Board Diagnosis System Description...643
Warning Light, Indicator Light Description...644
CAN Communication System Description...645
Schematic and Routing Diagram...646
Electronic Stability Program Schematic...646
Electronic Stability Program Wiring Circuit Diagram...647
Component Location...648
Electronic Stability Program Component Location...648
Diagnostic Information and Procedures...650
Electronic Stability Program Check...650
ESP‚ Warning Light Check...652
ABS Warning Light Check...652
EBD Warning Light (Brake Warning Light) Check...652
DTC Check...653
DTC Table...653
DTC Clearance...657
Fail-Safe Table...657
Scan Tool Data...659
Visual Inspection...660
ESP‚ Warning Light Does Not Come ON at Ignition Switch ON...661
ESP‚ Warning Light Comes ON Steady...662
ABS Warning Light Does Not Come ON at Ignition Switch ON...663
ABS Warning Light Comes ON Steady...663
EBD Warning Light (Brake Warning Light) Comes ON Steady...664
Serial Data Link Circuit Check...666
DTC C1016: Brake Light Switch...668
DTC C1017 / C1023: Lateral G Sensor / Yaw Rate Sensor...670
DTC C1020 / C1028: Master Cylinder Pressure Sensor Power Supply Failure / Circuit...670
DTC C1021 / C1022 / C1025 / C1026 / C1031 / C1032 / C1035 / C1036: Wheel Speed Sensor Circuit / Sensor or Encoder...671
DTC C1024: Steering Angle Sensor...673
DTC C1027: ESP‚ OFF Switch...673
DTC C1033: Wheel Speed Sensor Deviation...674
DTC C1034 / C1039: Yaw Rate / G Sensor Power Supply Failure / Internal Failure...676
DTC C1037: Steering Angle Sensor Power Supply Failure...677
DTC C1038: Steering Angle Sensor Detect Rolling Counter...678
DTC C1040: ESP‚ Continuous Operation...679
DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Inlet / Outlet / Cut / Suction Solenoid...679
DTC C1057: Power Supply Voltage Too High / Too Low...681
DTC C1061: Pump Motor Circuit...682
DTC C1063: Solenoid Valve Power Supply Driver Circuit...683
DTC C1071: Control Module Internal Defect...684
DTC C1075: Steering Angle Sensor Calibration...684
DTC C1091: CAN Invalid Data from ECM...685
DTC C1096: Yaw Rate / G Sensor Message Counter Error...685
DTC U0073: Control Module Communication Bus Off...686
DTC U0100: Lost Communication with ECM / PCM...686
DTC U0101: Lost Communication with TCM...686
DTC U0114: Lost Communication with Four-Wheel Drive Clutch Control Module...686
DTC U0123: Lost Communication with Yaw Rate Sensor Module...686
DTC U0126: Lost Communication with Steering Angle Sensor...686
ESP‚ Hydraulic Unit / Control Module Assembly Power and Ground Circuit Check...686
Repair Instructions...688
ESP‚ Hydraulic Unit Operation Check...688
Sensor Calibration...688
ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...689
ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation...689
Front Wheel Speed Sensor On-Vehicle Inspection...691
Front Wheel Speed Sensor Removal and Installation...691
Front Wheel Speed Sensor Inspection...691
Rear Wheel Speed Sensor On-Vehicle Inspection...691
Rear Wheel Speed Sensor Removal and Installation...691
Rear Wheel Speed Sensor Inspection...691
Front Wheel Speed Sensor Encoder On-Vehicle Inspection...691
Front Wheel Speed Sensor Encoder Removal and Installation...691
Rear Wheel Speed Sensor Encoder On-Vehicle Inspection...691
Rear Wheel Speed Sensor Encoder Removal and Installation...691
Master Cylinder Pressure Sensor On-Vehicle Inspection...691
Yaw Rate / G Sensor On-Vehicle Inspection...692
Yaw Rate / G Sensor Removal and Installation...693
Yaw Rate / G Sensor Inspection...694
Steering Angle Sensor On-Vehicle Inspection...694
Steering Angle Sensor Removal and Installation...695
Steering Angle Sensor Inspection...695
ESP‚ OFF Switch Removal and Installation...695
ESP‚ OFF Switch Inspection...695
Specifications...696
Tightening Torque Specifications...696
Special Tools and Equipment...696
Special Tool...696
Transmission / Transaxle...697
Precautions...700
Precautions...700
Precautions on Transmission / Transaxle...700
Automatic Transmission/Transaxle...701
Precautions...701
Precautions in Diagnosing Trouble...701
Precautions for Disassembly and Reassembly...701
General Description...703
A/T Description...703
Clutch / Brake / Planetary Gear Function of Automatic Transaxle...707
Table of Component Operation...708
Operation of Shift Solenoid Valves, Timing Solenoid Valve and TCC Solenoid Valve...708
Automatic Gear Shift Table...709
A/T Diagnosis General Description...711
On-Board Diagnostic System Description...711
CAN Communication System Description...712
Schematic and Routing Diagram...713
Transmission Control Module (TCM) Wiring Diagram...713
A/T System Diagram...715
Component Location...716
Electronic Shift Control System Components Location...716
Diagnostic Information and Procedures...717
A/T System Check...717
Visual Inspection...719
Malfunction Indicator Lamp (MIL) Check...720
Transmission Warning Light Check (Non-Euro-OBD model)...720
DTC Table...720
DTC Check...722
DTC Clearance...723
Fail-Safe Table...723
Scan Tool Data...725
A/T Basic Check...728
Road Test...728
Manual Road Test...731
Engine Brake Test...731
Stall Test...732
Time Lag Test...733
Line Pressure Test...734
“P” Range Test...735
A/T Symptom Diagnosis...735
Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON (Non-Euro- OBD Model)...743
Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON (Non- Euro-OBD Model)...743
DTC P0602: Control Module Programming Error...744
DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input)...744
DTC P0707: Transmission Range Sensor Circuit Low...746
DTC P0711: Transmission Fluid Temperature Sensor “A” Control Range / Performance...748
DTC P0712: Transmission Fluid Temperature Sensor Circuit Low...749
DTC P0713: Transmission Fluid Temperature Sensor Circuit High...750
DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction...752
DTC P0722: Output Speed Sensor (VSS) Circuit No Signal...753
DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON...755
DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction...756
DTC P0787: Shift / Timing Solenoid Control Circuit Low...757
DTC P0788: Shift / Timing Solenoid Control Circuit High...759
DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance...760
DTC P0962: Pressure Control Solenoid Control Circuit Low...762
DTC P0963: Pressure Control Solenoid Control Circuit High...764
DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low...766
DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High...768
DTC P1702: Internal Control Module Memory Check Sum Error...770
DTC P1723: Range Select Switch Malfunction...770
DTC P1878: Torque Converter Clutch Shudder...771
DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance...772
DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High...774
DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low...776
DTC U0073: Control Module Communication Bus Off...778
DTC U0100: Lost Communication with ECM / PCM “A”...778
Inspection of TCM and Its Circuits...778
TCM Power and Ground Circuit Check...782
Brake Interlock System Inspection...783
Repair Instructions...784
Learning Control Initialization...784
A/T Fluid Level Check...784
A/T Fluid Change...785
Select Lever Components...786
Select Lever Assembly Removal and Installation...786
Select Lever Knob Installation...786
Select Lever Inspection...787
“3” Position Switch Inspection...787
Shift Lock Solenoid Inspection...787
Shift Lock Solenoid Replacement...787
Select Cable Components...788
Select Cable Removal and Installation...788
Select Cable Adjustment...788
Key Interlock Cable Removal and Installation...789
Transmission Range Sensor Inspection and Adjustment...791
Output Shaft Speed Sensor (VSS) Removal and Installation...792
Output Shaft Speed Sensor (VSS) Inspection...792
Input Shaft Speed Sensor Removal and Installation...793
Input Shaft Speed Sensor Inspection...793
Transmission Fluid Temperature Sensor Removal and Installation...793
Transmission Fluid Temperature Sensor Inspection...794
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation...794
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Inspection...796
Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Solenoid) Removal and Installation...797
Pressure Control Solenoid Valves Inspection...798
Transmission Control Module (TCM) Removal and Installation...799
A/T Relay Inspection...799
Differential Side Oil Seal Replacement...800
A/T Fluid Cooler Hoses Replacement...800
Automatic Transaxle Unit Components...801
Automatic Transaxle Unit Dismounting and Remounting...802
Automatic Transaxle Assembly Components...804
Automatic Transaxle Unit Disassembly...806
Oil Pump Assembly Components...818
Oil Pump Assembly Disassembly and Reassembly...818
Oil Pump Assembly Inspection...819
Direct Clutch Assembly Components...821
Direct Clutch Assembly Preliminary Check...821
Direct Clutch Assembly Disassembly and Reassembly...822
Direct Clutch Assembly Inspection...824
Forward and Reverse Clutch Assembly Components...825
Forward and Reverse Clutch Assembly Preliminary Check...825
Forward and Reverse Clutch Assembly Disassembly and Reassembly...826
Forward and Reverse Clutch Assembly Inspection...829
2nd Brake Piston Assembly Components...830
2nd Brake Piston Assembly Disassembly and Reassembly...830
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components...831
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly...832
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection...833
Countershaft Assembly Components...834
Countershaft Assembly Disassembly and Reassembly...834
Valve Body Assembly Components...835
Valve Body Assembly Disassembly and Reassembly...836
Differential Assembly Components...837
Differential Assembly Disassembly and Reassembly...838
Differential Assembly Inspection...839
Torque Converter Housing Disassembly and Reassembly...840
Transaxle Case Disassembly and Reassembly...842
Automatic Transaxle Unit Inspection and Adjustment...843
Automatic Transaxle Unit Assembly...846
Specifications...863
Tightening Torque Specifications...863
Special Tools and Equipment...864
Recommended Service Material...864
Special Tool...864
Manual Transmission/Transaxle...867
General Description...867
Manual Transaxle Construction...867
Diagnostic Information and Procedures...871
Manual Transaxle Symptom Diagnosis...871
Repair Instructions...871
Manual Transaxle Oil Level Check...871
Manual Transaxle Oil Change...872
Differential Side Oil Seal Replacement...873
Gear Shift Control Lever and Cable Components...874
Gear Shift Control Lever and Cable Removal and Installation...875
Gear Select Control Cable Adjustment...875
Back Up Light Switch Removal and Installation...876
Back Up Light Switch Inspection...876
Manual Transaxle Unit Components...877
Manual Transaxle Unit Dismounting and Remounting...878
Gear Shift and Select Shaft Assembly Components...879
Gear Shift and Select Shaft Assembly Removal and Installation...880
Gear Shift and Select Shaft Assembly Disassembly and Reassembly...881
Manual Transaxle Assembly Components...882
Fifth Gear Disassembly and Reassembly...883
Manual Transaxle Assembly Disassembly and Reassembly...885
Right Case Disassembly and Reassembly...890
Left Case Disassembly and Reassembly...891
Input Shaft and Countershaft Components...893
Input Shaft Disassembly and Reassembly...894
Countershaft Disassembly and Reassembly...897
Gear Shift Shaft Components...901
5th and Reverse Gear Shift Shafts Disassembly and Reassembly...901
Gear Shift Shaft and Fork Inspection...901
Differential Components...902
Differential Disassembly and Reassembly...902
Specifications...904
Tightening Torque Specifications...904
Special Tools and Equipment...905
Recommended Service Material...905
Special Tool...905
Clutch...908
General Description...908
Clutch (Hydraulic Type) Construction...908
Diagnostic Information and Procedures...909
Clutch System Symptom Diagnosis...909
Repair Instructions...910
Clutch Pedal Inspection...910
Clutch Fluid Level Inspection...910
Air Bleeding of Clutch System...910
Clutch Fluid Pipe and Hose Components...911
Clutch Fluid Pipe Removal and Installation...911
Clutch Fluid Pipe Inspection...911
Clutch Master Cylinder Removal and Installation...912
Clutch Operating Cylinder Assembly Removal and Installation...912
Clutch Operating Cylinder Assembly Inspection...913
Clutch Cover, Clutch Disc and Flywheel Components...913
Clutch Cover, Clutch Disc and Flywheel Removal and Installation...914
Clutch Cover, Clutch Disc and Flywheel Inspection...915
Specifications...916
Tightening Torque Specifications...916
Special Tools and Equipment...917
Recommended Service Material...917
Special Tool...917
Steering...919
Precautions...921
Precautions...921
Precautions on Steering...921
Steering General Diagnosis...922
Precautions...922
Precautions for Steering Diagnosis...922
Diagnostic Information and Procedures...922
Steering Symptom Diagnosis...922
Steering System Inspection...923
Steering Wheel and Column...924
Precautions...924
Service Precautions of Steering Wheel and Column...924
General Description...924
Steering Wheel and Column Construction...924
Diagnostic Information and Procedures...925
Checking Steering Column for Accident Damage...925
Repair Instructions...926
Steering Wheel and Column Components...926
Steering Wheel Removal and Installation...927
Contact Coil Cable Assembly Removal and Installation...928
Centering Contact Coil Cable Assembly...929
Contact Coil Cable Assembly Inspection...929
Steering Angle Sensor Removal and Installation (ESP‚ model)...929
Steering Angle Sensor Inspection (ESP‚ model)...930
Steering Column Removal and Installation...930
Steering Column Inspection...931
Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)...932
Steering Lock Assembly (Ignition Switch) Removal and Installation...932
Steering Lower Shaft Removal and Installation...933
Specifications...934
Tightening Torque Specifications...934
Special Tools and Equipment...934
Special Tool...934
Power Assisted Steering System...935
Precautions...935
P/S System Note...935
Precautions in Diagnosing Troubles...935
General Description...936
P/S System Description...936
EPS Diagnosis General Description...937
On-Board Diagnostic System Description...937
Schematic and Routing Diagram...938
EPS System Wiring Circuit Diagram...938
Diagnostic Information and Procedures...939
EPS System Check...939
“EPS” Warning Light Check...942
DTC Check...942
DTC Clearance...943
DTC Table...943
Visual Inspection...945
Scan Tool Data...946
P/S System Symptom Diagnosis...947
DLC and Its Communication Check (No communication to P/S Control Module)...948
“EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts...950
“EPS” Warning Light Remains ON Steady after Engine Starts...952
DTC C1111 / C1113 / C1115: Torque Sensor Circuit Failure...953
DTC C1116: Steering Torque Sensor Power Supply Circuit...955
DTC C1121 / C1123 / C1124: Vehicle Speed Signal Circuit Failure...956
DTC C1122: Engine Speed Signal...958
DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure...960
DTC C1153: P/S Control Module Power Supply Circuit...961
DTC C1155: P/S Control Module Internal Failure...962
P/S Control Module Power Supply and Ground Circuit Check...963
Inspection of P/S Control Module and Its Circuits...964
Steering Wheel Play Check...968
Steering Force Check...968
Repair Instructions...969
Steering Gear Case Assembly Components...969
Tie-Rod End Boot On-Vehicle Inspection...970
Tie-Rod End Removal and Installation...970
Tie-Rod End Initial Position Setting...971
Tie-Rod End Inspection...971
Steering Shaft Joint On-Vehicle Inspection...971
Steering Gear Case Assembly Removal and Installation...972
Steering Rack Boot Inspection...973
Tie-Rod / Rack Boot Removal and Installation...973
Steering Rack Plunger Removal and Installation...974
Steering Rack Plunger Inspection...975
P/S Control Module Removal and Installation...975
Torque Sensor and Its Circuit Inspection...976
P/S Motor and Its Circuit Inspection...977
Specifications...978
Tightening Torque Specifications...978
Special Tools and Equipment...978
Recommended Service Material...978
Special Tool...978
HVAC...979
Precautions...982
Precautions...982
Precautions on HVAC...982
Heater and Ventilation...983
Schematic and Routing Diagram...983
Heater and Ventilation Diagram...983
Heater and Ventilation Wiring Circuit Diagram...984
Component Location...984
Electronic Control System Components Location...984
Diagnostic Information and Procedures...985
Heater and Ventilation Symptom Diagnosis...985
Repair Instructions...986
HVAC Unit Components...986
HVAC Unit Removal and Installation (Non-A/C)...986
Blower Motor Removal and Installation...986
Blower Motor Inspection...986
Blower Motor Resistor Removal and Installation...987
Blower Motor Resistor Inspection...987
Blower Motor Relay Inspection...988
HVAC Control Unit Components...988
HVAC Control Unit Removal and Installation...989
Blower Speed Selector Inspection...991
Air Intake Selector Inspection...991
Air Intake Control Actuator Removal and Installation...991
Air Intake Control Actuator Inspection...992
Center Ventilation Louver Removal and Installation...993
Side Ventilation Louver Removal and Installation...993
Rear Duct Removal and Installation (If Equipped)...994
HVAC Air Filter Removal and Installation (If Equipped)...994
HVAC Air Filter Inspection (If Equipped)...994
Air Conditioning System...995
Manual Type...995
Precautions...995
A/C System Caution...995
Precautions on Servicing A/C System...995
General Description...996
Sub-Cool A/C System Description...996
A/C Operation Description at ECM...997
Schematic and Routing Diagram...998
A/C System Air Flow Diagram...998
A/C System Wiring Diagram...999
Manual A/C Electronic Input Output Diagram...1000
Component Location...1000
A/C System Major Components Location...1000
Electronic Control System Components Location...1001
Diagnostic Information and Procedures...1002
A/C System Performance Inspection...1002
Trouble Diagnosis for Abnormal Pressure...1005
A/C System Inspection at ECM...1006
A/C System Symptom Diagnosis...1007
Abnormal Noise Symptom Diagnosis of A/C System...1009
Repair Instructions...1011
Operation Procedure for Refrigerant Charge...1011
Condenser Cooling Fan Removal and Installation...1016
Condenser Cooling Fan Inspection...1017
Condenser Assembly On-Vehicle Inspection...1017
Condenser Assembly Removal and Installation...1017
Desiccant Removal and Installation...1018
HVAC Unit Components...1019
HVAC Unit Removal and Installation...1020
Evaporator Inspection...1021
Evaporator Temperature Sensor Removal and Installation...1021
Evaporator Temperature Sensor Inspection...1022
Expansion Valve Removal and Installation...1022
Expansion Valve Inspection...1022
A/C Refrigerant Pressure Sensor and Its Circuit Inspection...1023
A/C Refrigerant Pressure Sensor Removal and Installation...1023
A/C Switch Inspection...1023
A/C System Relay Inspection...1024
Compressor Drive Belt Inspection and Adjustment...1024
Compressor Drive Belt Removal and Installation...1025
Compressor Assembly Removal and Installation...1025
Compressor Assembly Components...1026
Magnet Clutch Inspection...1026
Magnet Clutch Removal and Installation...1027
Thermal Switch Inspection...1029
Thermal Switch Removal and Installation...1029
Relief Valve Inspection...1029
Relief valve Removal and Installation...1029
Specifications...1030
Tightening Torque Specifications...1030
Special Tools and Equipment...1031
Recommended Service Material...1031
Special Tool...1031
Automatic Type...1032
Precautions...1032
A/C System Caution...1032
Precautions in Diagnosing Trouble...1032
Precautions on Servicing A/C System...1032
General Description...1032
Auto A/C System Description...1032
HVAC Control Description...1033
Sub-Cool A/C System Description...1033
On-Board Diagnostic System Description...1034
Schematic and Routing Diagram...1034
A/C System Air Flow Diagram...1034
A/C System Wiring Diagram...1035
Auto A/C Electronic Control Input / Output Diagram...1036
Component Location...1036
A/C System Major Components Location...1036
Electronic Control System Components Location...1037
Diagnostic Information and Procedures...1038
Air Conditioning System Check...1038
A/C System Symptom Diagnosis...1040
Abnormal Noise Symptom Diagnosis of A/C System...1042
DTC Check...1042
DTC Clearance...1043
DTC Table...1044
Fail-Safe Table...1046
Scan Tool Data...1048
Visual Inspection...1049
DTC B1502: Inside Air Temperature Sensor Circuit Malfunction...1050
DTC B1503: Evaporator Temperature Sensor Circuit Malfunction...1051
DTC B1504: Sunload Sensor Circuit Malfunction...1052
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction...1054
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction...1055
DTC B1513: Temperature Control Actuator (Motor) and/or Its Circuit Malfunction...1057
DTC B1514: Air Flow Control Actuator (Motor) and/or Its Circuit Malfunction...1058
DTC B1520 / B1521 / B1522: Temperature / Blower Speed / Air Flow Selector Malfunction...1059
DTC B1541: Back-Up Power Supply Circuit Malfunction...1060
DTC B1546: A/C Refrigerant Pressure Malfunction...1061
DTC B1551: Serial Communication Circuit Malfunction...1062
DTC B1552: HVAC Control Module Check Sum Error...1063
DTC B1553: CAN Communication Circuit Malfunction...1063
DTC B1557: VSS Signal Failure...1064
DTC B1561: ECT Signal Failure...1064
DTC B1562: Outside Air Temperature Signal Failure...1065
DTC B1563: A/C Refrigerant Pressure Signal Failure...1065
DTC B1570: Engine Type Signal Failure...1066
DTC B1571: Combination Meter Spec Signal Failure...1066
Inspection of HVAC Control Module and Its Circuit...1067
A/C System Inspection at ECM...1070
Repair Instructions...1070
Operation Procedure for Refrigerant Charge...1070
HVAC Unit Components...1071
HVAC Unit Removal and Installation...1072
Temperature Control Actuator Removal and Installation...1072
Temperature Control Actuator and Its Circuit Inspection...1072
Air Flow Control Actuator Removal and Installation...1074
Air Flow Control Actuator and Its Circuit Inspection...1074
Air Intake Actuator Removal and Installation...1075
Air Intake Actuator Inspection...1075
Actuator Linkage Inspection...1075
Blower Motor Controller Removal and Installation...1075
Blower Motor Controller Inspection...1076
HVAC Control Module Removal and Installation...1076
Sunload Sensor Removal and Installation...1076
Sunload Sensor Inspection...1077
Outside Air Temperature Sensor Removal and Installation...1077
Outside Air Temperature Sensor Inspection...1077
Inside Air Temperature Sensor Removal and Installation...1077
Inside Air Temperature Sensor Inspection...1077
Condenser Cooling Fan Relay Inspection...1078
Condenser Cooling Fan Removal and Installation...1078
Condenser Cooling Fan Inspection...1078
Condenser Assembly On-Vehicle Inspection...1078
Condenser Assembly Removal and Installation...1078
Evaporator Inspection...1078
Evaporator Temperature Sensor Removal and Installation...1078
Evaporator Temperature Sensor Inspection...1078
Expansion Valve Removal and Installation...1078
Expansion Valve Inspection...1078
A/C Refrigerant Pressure Sensor and Its Circuit Inspection...1078
A/C Refrigerant Pressure Sensor Removal and Installation...1078
Compressor Relay Inspection...1078
Compressor Drive Belt Inspection and Adjustment...1078
Compressor Drive Belt Removal and Installation...1078
Compressor Assembly Removal and Installation...1078
Compressor Assembly Components...1078
Magnet Clutch Removal and Installation...1078
Magnet Clutch Inspection...1078
Thermal Switch Inspection...1078
Thermal Switch Removal and Installation...1078
Relief Valve Inspection...1078
Special Tools and Equipment...1079
Recommended Service Material...1079
Special Tool...1079
Restraint...1081
Precautions...1083
Precautions...1083
Precautions on Restraint...1083
Seat Belts...1084
Precautions...1084
Precautions on Service and Diagnosis of Seat Belt...1084
General Description...1085
Seat Belt Construction...1085
Diagnostic Information and Procedures...1087
Repair and Inspection Required after Accident...1087
Repair Instructions...1088
Front Seat Belt Components...1088
Front Seat Belt Removal and Installation...1089
Front Seat Belt Inspection...1090
Rear Seat Belt Components...1091
Rear Seat Belt Removal and Installation...1093
Rear Seat Belt Inspection...1093
Specifications...1093
Tightening Torque Specifications...1093
Air Bag System...1094
Precautions...1094
Precautions on Service and Diagnosis of Air Bag System...1094
Precautions on Handling and Storage of Air Bag System Components...1094
Precautions on Disposal of Air Bag and Seat Belt Pretensioner...1098
General Description...1098
Air Bag System Construction...1098
Air Bag System Input / Output Table...1099
Schematic and Routing Diagram...1100
Air Bag System Wiring Circuit Diagram...1100
Air Bag System Input / Output Diagram...1102
Component Location...1103
Air Bag System Components, Wiring and Connectors Location...1103
Diagnostic Information and Procedures...1104
Air Bag Diagnostic System Check...1104
Air Bag Diagnostic System Check Flow...1105
DTC Table...1106
DTC Check...1110
DTC Clearance...1110
Scan Tool Data...1110
“AIR BAG” Warning Light Comes ON Steady...1111
“AIR BAG” Warning Light Does Not Come ON...1114
Serial Data Link Circuit Check...1115
DTC B1013: SDM Internal Failure...1117
DTC B1014: “AIR BAG” Warning Light Circuit...1118
DTC B1016: Power Supply Voltage too High...1118
DTC B1017: Power Supply Voltage too Low...1119
DTC B1021: Front Air Bag Deployment Record...1120
DTC B1024 / B1025: Side Air-Bag Deployment Record...1121
DTC B1026: Seat Belt Pretensioner Activation Record...1121
DTC B1027: Number of Deployment Times Exceeded Limit...1122
DTC B1031: Driver Air Bag Circuit High Resistance...1123
DTC B1032: Driver Air Bag Circuit Low Resistance...1125
DTC B1033: Driver Air Bag Circuit Shorted to Ground...1127
DTC B1034: Driver Air Bag Circuit Shorted to Power Supply...1129
DTC B1041: Passenger Air Bag Circuit High Resistance...1132
DTC B1042: Passenger Air Bag Circuit Low Resistance...1135
DTC B1043: Passenger Air Bag Circuit Shorted to Ground...1137
DTC B1044: Passenger Air Bag Circuit Shorted to Power Supply...1138
DTC B1051 / B1055: Seat Belt Pretensioner Circuit High Resistance...1140
DTC B1052 / B1056: Seat Belt Pretensioner Circuit Low Resistance...1143
DTC B1053 / B1057: Seat Belt Pretensioner Shorted to Ground...1144
DTC B1054 / B1058: Seat Belt Pretensioner Circuit Shorted to Power Supply...1146
DTC B1061 / B1065: Side-Air Bag Circuit High Resistance...1147
DTC B1062 / B1066: Side-Air Bag Circuit Low Resistance...1151
DTC B1063 / B1067: Side-Air Bag Circuit Shorted to Ground...1153
DTC B1064 / B1068: Side-Air Bag Circuit Shorted to Power Supply...1156
DTC B1071: Driver Forward Impact-Sensor Communication Data Inconsistent...1158
DTC B1072: Driver Forward Impact-Sensor Communication Data Invalid...1158
DTC B1073: Driver Forward Impact-Sensor Circuit Shorted to Ground...1159
DTC B1074: Driver Forward Impact-Sensor Circuit Open...1160
DTC B1081 / B1091: Side Impact-Sensor No Response...1162
DTC B1082 / B1092: Side Impact-Sensor Communication DATA Invalid...1162
DTC B1083 / B1093: Side Impact-Sensor Circuit Shorted to Ground...1163
DTC B1084 / B1094: Side Impact-Sensor Circuit Open...1165
DTC B1085 / B1095: Side Impact-Sensor Communication DATA Inconsistent...1166
DTC B1361 / B1365: Curtain-Air Bag Circuit High Resistance...1167
DTC B1362 / B1366: Curtain-Air Bag Circuit Low Resistance...1171
DTC B1363 / B1367: Curtain-Air Bag Circuit Shorted to Ground...1174
DTC B1364 / B1368: Curtain-Air Bag Circuit Shorted to Power Supply...1176
SDM Power Supply and Ground Circuit Check...1178
Contact Coil Cable and Its Circuit Check...1180
Inspection of Intermittent and Poor Connections...1183
Repair and Inspection Required after Accident...1184
Repair Instructions...1187
Disabling Air Bag System...1187
Enabling Air Bag System...1188
SDM Removal and Installation...1188
SDM Inspection...1190
Driver Air Bag (Inflator) Module Removal and Installation...1190
Driver Air Bag (Inflator) Module Inspection...1191
Passenger Air Bag (Inflator) Module Removal and Installation...1191
Passenger Air Bag (Inflator) Module Inspection...1193
Side-Air Bag (Inflator) Module Removal and Installation...1194
Side-Air Bag (Inflator) Inspection...1196
Side Curtain-Air Bag (Inflator) Module Removal and Installation...1196
Side Curtain-Air Bag (Inflator) Module Inspection...1198
Forward Impact-Sensor Removal and Installation...1199
Forward Impact-Sensor Inspection...1200
Side Impact-Sensor Removal and Installation...1200
Side Impact-Sensor Inspection...1201
Passenger Air Bag (Inflator) Module Repair Harness Installation...1201
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal...1202
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal...1213
Specifications...1214
Tightening Torque Specifications...1214
Special Tools and Equipment...1214
Use of Special Tools...1214
Special Tool...1216
Body, Cab and Accessories...1217
Precautions...1223
Precautions...1223
Precautions on Body, Cab and Accessories...1223
Precautions for Body Service...1223
Fastener Caution for Body Service...1223
Wiring Systems...1224
Precautions...1224
Cautions in Body Electrical System Servicing...1224
General Description...1224
Abbreviations...1224
Wire / Connector Color Symbols...1224
Symbols and Marks...1225
How to Read Connector Layout Diagram...1227
How to Read Connector Codes and Terminal Nos...1228
How to Read Ground Point...1231
How to Read Power Supply Diagram...1232
How to Read System Circuit Diagram...1232
Connector Layout Diagram...1234
Connector Layout Diagram...1234
Engine Compartment...1234
Instrument Panel...1245
Door, Roof...1251
Floor...1255
Rear...1265
Ground Point...1266
Ground (earth) Point...1266
Power Supply Diagram...1267
Power Supply Diagram...1267
Fuses and the Protected Parts...1269
Fuses in Main Fuse Box...1269
Individual Circuit Fuse Box No. 1...1270
Individual Circuit Fuse Box No. 2 (In J/B (Except Taiwan))...1271
Individual Circuit Fuse Box No. 2 (In J/B (Taiwan))...1273
Individual Circuit Fuse Box No.3 (Sedan)...1275
Junction Block (J/B) Connector / Fuse Layout...1276
Junction Block Inner Circuit (Overview (Except Taiwan))...1277
Junction Block Inner Circuit (Detail (Except Taiwan))...1279
Junction Block Inner Circuit (Overview (Taiwan))...1284
Junction Block Inner Circuit (Detail (Taiwan))...1286
System Circuit Diagram...1291
System Circuit Diagram...1291
A-1 Cranking System Circuit Diagram...1293
A-2 Charging System Circuit Diagram...1294
A-3 Ignition System Circuit Diagram (M15A engine, M16A engine)...1295
A-3 Ignition System Circuit Diagram (J20A engine)...1296
A-4 Cooling System Circuit Diagram (M15A engine, M16A engine)...1297
A-4 Cooling System Circuit Diagram (J20A engine)...1298
A-5 Engine and A/C Control System Circuit Diagram (M15A engine)...1299
A-5 Engine and A/C Control System Circuit Diagram (M16A engine)...1303
A-5 Engine and A/C Control System Circuit Diagram (J20A engine)...1307
A-6 A/T Control System Circuit Diagram...1311
A-7 Immobilizer System Circuit Diagram...1313
A-8 Body Control System Circuit Diagram (Except Taiwan)...1314
A-8 Body Control System Circuit Diagram (Taiwan)...1318
A-10 4WD Control System (Except Taiwan)...1322
B-1 Windshield Wiper and Washer Circuit Diagram...1323
B-2 Rear Wiper and Washer Circuit Diagram (Except Taiwan)...1324
B-2 Rear Wiper and Washer Circuit Diagram (Taiwan)...1325
B-3 Rear Defogger Circuit Diagram (Hatchback (Except Taiwan))...1326
B-3 Rear Defogger Circuit Diagram (Hatchback (Taiwan))...1327
B-3 Rear Defogger Circuit Diagram (Sedan)...1328
B-4 Power Window Circuit Diagram...1329
B-5 Power Door Lock Circuit Diagram (Except Taiwan)...1331
B-5 Power Door Lock Circuit Diagram (Taiwan)...1333
B-6 Power Mirror Circuit Diagram (Hatchback (Except Taiwan))...1335
B-6 Power Mirror Circuit Diagram (Hatchback (Taiwan))...1336
B-6 Power Mirror Circuit Diagram (Sedan (Except Taiwan))...1337
B-6 Power Mirror Circuit Diagram (Sedan (Taiwan))...1338
B-7 Horn Circuit Diagram...1339
B-8 Seat Heater Circuit Diagram...1340
B-9 Keyless Start System Circuit Diagram...1341
C-1 Combination Meter Circuit Diagram (Meter)...1342
C-2 Combination Meter Circuit Diagram (Indicator)...1343
C-3 Combination Meter Circuit Diagram (Warning Light)...1344
D-1 Headlight System Circuit Diagram (Except Taiwan)...1346
D-1 Headlight System Circuit Diagram (Taiwan)...1348
D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Hatchback (Except Taiwan))...1349
D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Sedan (Except Taiwan))...1350
D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Hatchback (Taiwan))...1351
D-2 Position, Tail and Licence Plate Light System Circuit Diagram (Sedan (Taiwan))...1352
D-3 Front Fog Light System Circuit Diagram (Except Taiwan)...1353
D-3 Front Fog Light System Circuit Diagram (Taiwan)...1354
D-4 Illumination Light System Circuit Diagram (Except Taiwan)...1355
D-4 Illumination Light System Circuit Diagram (Taiwan)...1356
D-5 Interior Light System Circuit Diagram (Hatchback (Except Taiwan))...1357
D-5 Interior Light System Circuit Diagram (Hatchback (Taiwan))...1358
D-5 Interior Light System Circuit Diagram (Sedan (Except Taiwan))...1359
D-5 Interior Light System Circuit Diagram (Sedan (Taiwan))...1360
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Hatchback (Except Taiwan))...1361
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Sedan (Except Taiwan))...1363
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Hatchback (Taiwan))...1365
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram (Sedan (Taiwan))...1367
D-7 Brake Light System Circuit Diagram (Hatchback)...1369
D-7 Brake Light System Circuit Diagram (Sedan)...1370
D-8 Back-Up Light System Circuit Diagram (Hatchback)...1371
D-8 Back-Up Light System Circuit Diagram (Sedan)...1372
D-9 Headlight Beam Leveling System Circuit Diagram (Manual Leveling)...1373
D-10 Rear Fog Light Circuit Diagram (Hatchback)...1374
D-10 Rear Fog Light Circuit Diagram (Sedan)...1375
E-1 Heater System Circuit Diagram...1376
E-2 Auto A/C System Circuit Diagram...1378
F-1 Air-Bag System Circuit Diagram (4ch)...1380
F-1 Air-Bag System Circuit Diagram (8ch)...1381
F-2 Anti-Lock Brake System Circuit Diagram...1383
F-3 Electronic Stability Program System Circuit Diagram...1385
F-4 Power Steering System Circuit Diagram...1387
G-1 Audio System Circuit Diagram...1389
G-2 Multi Information Display / Accessory Socket System Circuit Diagram...1391
G-4 Navigation System Circuit Diagram...1392
List of Connector...1394
List of Connectors...1394
C Connector...1394
E Connector...1395
G Connector...1397
J Connector...1399
K Connector...1400
L Connector...1400
M Connector (Sedan)...1403
O Connector (Hatchback)...1403
Q Connector (8ch)...1404
R Connector...1404
S Connector...1404
Lighting Systems...1405
Precautions...1405
Precautions for Discharge Headlight Service (If Equipped)...1405
Precautions in Diagnosing Troubles (Headlight Auto Leveling System)...1405
General Description...1405
Discharge Headlight Description (If Equipped)...1405
Headlight Auto Leveling System Description (If Equipped)...1406
Auto-On Headlight System Description (If Equipped)...1408
Schematic and Routing Diagram...1409
Headlight Auto Leveling System Wiring Circuit Diagram...1409
Component Location...1409
Lighting System Components Location...1409
Interior Light System Location...1411
Diagnostic Information and Procedures...1411
Self-Diagnosis Function for Headlight Auto Leveling System...1411
Headlight Leveling Warning Light Check...1412
Headlight Symptom Diagnosis (Discharge Headlight Model)...1412
Headlight Symptom diagnosis (Other than Discharge Headlight Model)...1413
Auto-On Headlight System Symptom Diagnosis (If Equipped)...1413
DRL System Symptom Diagnosis (If Equipped)...1414
Headlight Auto Leveling System Symptom Diagnosis (If Equipped)...1414
Headlight Manual Leveling System Symptom Diagnosis (If Equipped)...1414
Turn Signal and Hazard Warning Light Symptom Diagnosis...1415
Clearance, Tail and License Plate Light Symptom Diagnosis...1415
Back-Up Light Symptom Diagnosis...1416
Brake Light Symptom Diagnosis...1416
Front Fog Light Symptom Diagnosis (If Equipped)...1416
Rear Fog Light Symptom Diagnosis (If Equipped)...1416
Illumination Cancel System Symptom Diagnosis (If Equipped)...1417
Interior Light Symptom Diagnosis...1417
DRL Operation Inspection (If Equipped)...1417
Inspection of DRL Controller and Its Circuits (If Equipped)...1418
Auto-On Headlight Operation Inspection (If Equipped)...1419
Inspection of Auto-On Headlight Controller and Its Circuit (If Equipped)...1419
Inspection of Headlight Leveling Control Module and Its Circuit (Headlight Auto Leveling System)...1420
Repair Instructions...1422
Headlight Housing Removal and Installation...1422
Headlight Bulb Replacement (Discharge Headlight Model)...1423
Ballast Removal and Installation (Discharge Headlight Model)...1423
Igniter Removal and Installation (Discharge Headlight Model)...1424
Headlight Aiming Adjustment with Screen...1424
Headlight Switch (in Lighting Switch) Removal and Installation...1426
Headlight Switch (in Lighting Switch) Inspection...1426
Hazard Warning Switch Removal and Installation...1427
Hazard Warning Switch Inspection...1427
Brake Light Switch Inspection...1427
Turn Signal Light Switch (in Lighting Switch) Removal and Installation...1428
Turn Signal Light Switch (in Lighting Switch) Inspection...1428
Turn Signal and Hazard Warning Relay Removal and Installation...1428
Turn Signal and Hazard Warning Relay Inspection...1429
License Light Assembly Removal and Installation (Hatchback)...1429
License Light Removal and Installation (Sedan)...1430
Front Fog Light Assembly Removal and Installation (If Equipped)...1430
Front Fog Light Switch Inspection (If Equipped)...1431
Front Fog Light Aiming Adjustment with Screen (If Equipped)...1431
Rear Fog Light Switch Inspection (If Equipped)...1432
Headlight Manual Levering Switch Inspection (If Equipped)...1433
Headlight Leveling Actuator Inspection (If Equipped)...1433
Height Sensor Removal and Installation (If Equipped)...1434
Height Sensor and Its Circuit Inspection (If Equipped)...1435
Headlight Leveling Control Module Removal and Installation (If Equipped)...1435
Initialization of Headlight Auto Leveling System...1435
Auto-On Headlight Sensor Inspection (If Equipped)...1436
Illumination Cancel Switch Inspection (If Equipped)...1437
Tail Light Relay, Headlight Relay, Front Fog Light Relay Inspection (If Equipped)...1437
Specifications...1438
Tightening Torque Specifications...1438
Instrumentation / Driver Info. / Horn...1439
Precautions...1439
Precautions in Diagnosing Troubles for Combination Meter...1439
General Description...1439
CAN Communication System Description...1439
Auto Volume Control System Description (If Equipped)...1441
Schematic and Routing Diagram...1442
Combination Meter Circuit Diagram...1442
Component Location...1444
Audio System Component Location...1444
Diagnostic Information and Procedures...1445
Speedometer and VSS Symptom Diagnosis...1445
Tachometer Symptom Diagnosis...1445
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis...1445
Fuel Meter Symptom Diagnosis...1445
Low Fuel Warning Light Symptom Diagnosis...1446
Oil Pressure Warning Light Symptom Diagnosis...1446
Brake and Parking Brake Warning Light Symptom Diagnosis...1447
Seat Belt Reminder Light Symptom Diagnosis...1447
A/T Shift Position Indicator Symptom Diagnosis (A/T Model)...1447
Charge Warning Light Symptom Diagnosis...1448
Main Beam (High Beam) Indicator Symptom Diagnosis...1448
Warning Buzzer Circuit Symptom Diagnosis...1448
Cigarette Lighter Symptom Diagnosis (If Equipped)...1449
Horn Symptom Diagnosis...1449
Information Display Symptom Diagnosis (If Equipped)...1449
Clock System Diagnosis (If Equipped)...1450
Audio System Symptom Diagnosis (If Equipped)...1451
Remote Audio Control Switch Symptom Diagnosis (If Equipped)...1452
Navigation Symptom Diagnosis (If Equipped)...1452
Repair Instructions...1453
Ignition Switch Removal and Installation...1453
Ignition Switch Inspection...1453
Combination Meter Removal and Installation...1453
Fuel Level Sensor Removal and Installation...1454
Fuel Level Sensor Inspection...1454
Oil Pressure Switch Removal and Installation...1454
Oil Pressure Switch Inspection...1454
Engine Coolant Temperature (ECT) Sensor Inspection...1455
Brake Fluid Level Switch Inspection...1455
Parking Brake Switch Inspection...1455
Door Switch (Front / Rear Door) Inspection...1455
Rear End Door Switch Inspection (Hatchback)...1455
Trunk Lid Switch Inspection (Sedan)...1456
Outside Air Temperature Sensor Removal and Installation (If Equipped)...1456
Outside Air Temperature Sensor Inspection (If Equipped)...1456
Instrument Panel Removal and Installation...1456
Information Display (Clock) Removal and Installation...1458
Audio Unit Removal and Installation (If Equipped)...1458
Front Speaker Removal and Installation (If Equipped)...1458
Rear Speaker Removal and Installation (If Equipped)...1459
GPS Antenna Removal and Installation (If Equipped)...1459
Horn Removal and Installation...1459
Horn Inspection...1459
Horn Relay Inspection...1460
Antenna Base Removal and Installation (Hatchback)...1460
Remote Audio Control Switch Removal and Installation (If Equipped)...1460
Remote Audio Control Switch Inspection (If Equipped)...1461
Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...1461
Specifications...1461
Tightening Torque Specifications...1461
Wipers / Washers...1462
Diagnostic Information and Procedures...1462
Front Wiper and Washer Symptom Diagnosis...1462
Rear Wiper and Washer Symptom Diagnosis...1462
Repair Instructions...1463
Wipers and Washers Components...1463
Washer Tank and Washer Pump Removal and Installation...1464
Washer Pump Inspection...1464
Windshield Wiper Removal and Installation...1464
Windshield Wiper Motor Inspection...1465
Rear Wiper Removal and Installation...1467
Rear Wiper Motor Inspection...1468
Windshield Wiper and Washer Switch Removal and Installation...1469
Windshield Wiper and Washer Switch Inspection...1469
Rear Wiper and Washer Switch Removal and Installation...1471
Rear Wiper and Washer Switch Inspection...1471
Rear Wiper Relay Removal and Installation...1471
Rear Wiper Relay Inspection...1471
Specifications...1472
Tightening Torque Specifications...1472
Glass / Windows / Mirrors...1473
Precautions...1473
Precautions for Power Window Service (Pinching Prevention Function Model)...1473
General Description...1473
Rear End Door Window / Back Window Defogger System Description...1473
Schematic and Routing Diagram...1474
Power Window Circuit Diagram (Pinching Prevention Function Model)...1474
Diagnostic Information and Procedures...1475
Rear End Door Window / Back Window Defogger Symptom Diagnosis...1475
Power Window Control System Symptom Diagnosis...1475
Inspection of Pinching Prevention Function (Pinching Prevention Function Model)...1476
Power Door Mirror Control System Symptom Diagnosis...1476
Door Mirror Heater Symptom Diagnosis (If Equipped)...1477
Repair Instructions...1477
Windshield Components...1477
Windshield Removal and Installation...1478
Front Pillar Window Components...1482
Front Pillar Window Removal and Installation...1482
Rear Quarter Window Components (Hatchback Model)...1483
Rear Quarter Window Removal and Installation (Hatchback Model)...1483
Rear End Door Window Components (Hatchback Model)...1484
Rear End Door Glass Removal and Installation (Hatchback Model)...1484
Back Window Components (Sedan Model)...1485
Back Window Removal and Installation (Sedan Model)...1485
Front Door Window Components...1486
Front Door Glass Removal and Installation...1487
Front Door Window Regulator Removal and Installation...1488
Front Door Window Regulator Inspection...1488
Rear Door Window Components...1489
Rear Door Glass Removal and Installation...1490
Rear Door Window Regulator Removal and Installation...1491
Rear Door Window Regulator Inspection...1492
Rear End Door Window / Back Window Defogger Switch Inspection...1492
Rear End Door Window / Back Window Defogger Relay Inspection...1492
Rear End Door Window / Back Window Defogger Wire Inspection...1493
Rear End Door Window / Back Window Defogger Wire Repair...1494
Power Window Main Switch Inspection...1494
Power Window Sub Switch Inspection...1496
Pulse Sensor and Its Circuit Inspection (Pinching Prevention Function Model)...1497
Power Window Main Switch Initialization (Pinching Prevention Function Model)...1498
Door Mirror Components...1498
Door Mirror Removal and Installation...1499
Power Door Mirror Switch Inspection...1499
Power Door Mirror Actuator Inspection...1499
Door Mirror Heater Inspection (If Equipped)...1499
Door Mirror Heater Switch Inspection (If Equipped)...1500
Special Tools and Equipment...1500
Recommended Service Material...1500
Security and Locks...1501
General Description...1501
Key Coding Construction...1501
Rear End Door Opener System Description...1501
Component Location...1502
Power Door Lock and Keyless Entry System Component Location...1502
Diagnostic Information and Procedures...1503
Power Door Lock System Symptom Diagnosis...1503
Power Door Lock System Operation Inspection...1503
Keyless Entry System Symptom Diagnosis...1504
Keyless Entry System Operation Inspection...1505
Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...1505
Rear End Door Opener System Symptom Diagnosis...1505
Rear End Door Opener System Operation Inspection...1505
Repair Instructions...1506
Front Door Lock Assembly Components...1506
Front Door Lock Assembly Removal and Installation...1506
Front Door Lock Assembly Inspection...1508
Power Door Lock Switch Inspection...1508
Door Key Cylinder Switch Inspection...1508
Power Door Lock Actuator Inspection...1509
Rear Door Lock Assembly Components...1510
Rear Door Lock Assembly Removal and Installation...1510
Rear Door Lock Assembly Inspection...1510
Rear End Door Lock Assembly Components (Hatchback Model)...1511
Rear End Door Lock Assembly Removal and Installation (Hatchback Model)...1512
Rear End Door Lock Assembly Inspection (Hatchback Model)...1512
Rear End Door Opener Switch Inspection (Hatchback Model)...1513
Trunk Lid Lock Assembly Components (Sedan Model)...1513
Trunk Lid Lock Assembly Removal and Installation (Sedan Model)...1514
Trunk Lid Lock Assembly Inspection (Sedan Model)...1515
Replacement of Transmitter Battery (Other than Keyless Start Model)...1515
Programming Transmitter Code for Keyless Entry System (Other than Keyless Start Model)...1515
Keyless Entry Answer Back Function Change- over Procedure...1516
Keyless Entry Receiver Removal and Installation...1516
Keyless Entry Receiver and Its Circuit Inspection...1517
Specifications...1518
Tightening Torque Specifications...1518
Special Tools and Equipment...1518
Recommended Service Material...1518
Seats...1519
Diagnostic Information and Procedures...1519
Front Seat Heater Symptom Diagnosis (If Equipped)...1519
Repair Instructions...1520
Front Seat Components...1520
Front Seat Removal and Installation...1521
Front Seat Heater Switch (Driver and Passenger Side) Inspection (If Equipped)...1521
Front Seat Heater Wire Inspection (If Equipped)...1521
Rear Seat Components...1522
Rear Seat Removal and Installation...1524
Specifications...1524
Tightening Torque Specifications...1524
Special Tools and Equipment...1524
Recommended Service Material...1524
Interior Trim...1525
Repair Instructions...1525
Floor Carpet Removal and Installation...1525
Head Lining Removal and Installation...1526
Console Box Components...1528
Specifications...1528
Tightening Torque Specifications...1528
Hood / Fenders / Doors...1529
Repair Instructions...1529
Hood Removal and Installation...1529
Hood Inspection and Adjustment...1529
Front Fender Components...1530
Front Fender Removal and Installation...1530
Front Door Assembly Components...1531
Front Door Assembly Removal and Installation...1531
Rear Door Assembly Components...1533
Rear Door Assembly Removal and Installation...1533
Rear End Door Assembly Components (Hatchback Model)...1534
Rear End Door Assembly Removal and Installation (Hatchback Model)...1535
Trunk Lid Components (Sedan Model)...1536
Trunk Lid Removal and Installation (Sedan Model)...1537
Specifications...1539
Tightening Torque Specifications...1539
Special Tools and Equipment...1539
Recommended Service Material...1539
Body Structure...1540
Repair Instructions...1540
Front Bumper and Rear Bumper Components...1540
Radiator Grille Removal and Installation...1541
Front Bumper Extension Removal and Installation (if equipped)...1542
Rear Bumper Extension Removal and Installation (if equipped)...1543
Cowl Top and Front Lower Crossmember Components...1544
Specifications...1545
Body Dimensions...1545
Panel Clearance...1557
Tightening Torque Specifications...1558
Paint / Coatings...1559
General Description...1559
Anti-Corrosion Treatment Construction...1559
Plastic Parts Finishing...1559
Component Location...1560
Sealant Application Areas...1560
Under Coating Application Areas...1568
Anti-Corrosion Compound Application Area...1570
Exterior Trim...1572
Repair Instructions...1572
Roof Molding Removal and Installation...1572
Splash Guard Removal and Installation (If Equipped)...1573
Specifications...1573
Tightening Torque Specifications...1573
Control Systems...1575
Precautions...1577
Precautions...1577
Precautions for Control Systems...1577
Body Electrical Control System...1578
Precautions...1578
Precautions in Diagnosing Trouble...1578
General Description...1578
BCM General Description...1578
CAN Communication System Description...1579
Theft Deterrent Light Description...1580
Security Alarm Description (If Equipped)...1580
Schematic and Routing Diagram...1581
Body Electrical Control System Wiring Circuit Diagram...1581
Connector Layout Diagram of BCM and Junction Block...1584
Component Location...1585
BCM and Related System Component Location...1585
Diagnostic Information and Procedures...1586
BCM Self-Diagnosis Function...1586
Body Electrical Control System Check...1587
Scan Tool Data...1589
DTC Table...1591
DTC Check...1592
DTC Clearance...1593
BCM Power Circuit and Ground Circuit Check...1594
DTC B1133 (No. 1133): Battery Voltage Too High...1595
DTC B1141 / B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction...1596
DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction...1597
DTC B1157 (No. 1157): Air Bag Deployment Signal Input...1598
DTC B1170 (No. 1170): EEPROM Access Error...1598
DTC U0073 (No. 0073): Control Module Communication Bus Off...1598
DTC U0100 (No. 0100): Lost Communication with ECM...1598
DTC U0101 (No. 0101): Lost Communication with TCM...1598
DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module...1598
DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...1598
Inspection of BCM and Its Circuits...1599
Repair Instructions...1606
BCM (Included in Junction Block) Removal and Installation...1606
Security Alarm Mode Selection Procedure (If Equipped)...1607
Outside Air Temperature Sensor Removal and Installation...1607
Outside Air Temperature Sensor Inspection...1607
Special Tools and Equipment...1607
Special Tool...1607
Immobilizer Control System...1608
Precautions...1608
Precautions in Diagnosing Troubles...1608
Precaution in Replacing ECM...1608
Precaution in Replacing Ignition Key...1608
Precautions in Handling Immobilizer Control System...1608
General Description...1609
Immobilizer Control System Introduction...1609
On-Board Diagnostic System Description (Self-diagnosis Function)...1609
Schematic and Routing Diagram...1610
Immobilizer Control System Wiring Circuit Diagram...1610
Component Location...1612
Immobilizer Control System Components Location...1612
Diagnostic Information and Procedures...1612
Immobilizer Control System Check...1612
DTC Check...1613
DTC Clearance...1613
DTC Table...1614
Scan Tool Data...1615
Immobilizer Indicator Light Does Not Come ON with Ignition Switch ON and Engine Stop...1616
Immobilizer Indicator Light Remains ON after Engine Start...1617
DTC P1614: Transponder Response Error...1617
DTC P1615: Steering Lock Unit Communication Error...1618
DTC P1616: Unregistered Keyless Start Control Module...1619
DTC P1618: Keyless Start Control Module CAN Communication Error...1620
DTC P1621: Immobilizer Communication Line Error...1620
DTC P1622: EEPROM Reading / Writing Error...1621
DTC P1623: Unregistered Transponder...1621
DTC P1625: Immobilizer Antenna Error...1622
DTC P1636: Immobilizer Information Registration Failure...1622
DTC P1638: Immobilizer Information Mismatched...1623
Inspection of ICM and Its Circuit...1624
Repair Instructions...1626
ICM Removal and Installation...1626
Registration of the Ignition Key...1626
Procedure after ECM Replacement...1626
Special Tools and Equipment...1627
Special Tool...1627
Keyless Start System...1628
Precautions...1628
Precautions in Diagnosing Troubles...1628
General Description...1629
Keyless Start System Description...1629
Parts and Functions...1630
Keyless Engine Start Function...1631
Door Lock Function of Keyless Start System...1632
Trunk Lid Opener Function of Keyless Start System (Sedan)...1633
Operation Area of Remote Controller...1634
Alarm Function...1635
CAN Communication System Description...1635
Schematic and Routing Diagram...1636
Keyless Start System Electric Wiring Circuit Diagram...1636
Diagnostic Information and Procedures...1637
Self-Diagnosis Function...1637
Keyless Start System Diagnosis Introduction...1637
Keyless Start System Check...1637
Customer Questionnaire (Example)...1638
Key Indicator Light Check...1638
DTC Check...1639
DTC Table...1640
DTC Clearance...1640
Keyless Start System Symptom Diagnosis...1641
Keyless Start System Operation Inspection...1643
Door Lock Operation (Keyless Start System)...1643
Inspection of Keyless Start Control Module and Its Circuits...1643
No DTC Detection After Performing DTC Check...1649
Key Indicator Light Circuit Check (Key Indicator Light Doesn’t Light when Ignition Knob Switch is Pushed)...1650
Keyless Start Control Module Power and Ground Circuit Check...1652
DTC No. 11: Communication Error with Steering Lock Unit...1653
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...1654
DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM Reading Error) / (EEPROM Writing Error)...1654
DTC No. 31: Lost Communication with BCM...1655
DTC No. 33: Control Module Communication Bus Off...1655
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door / Trunk Lid Request Switch Failure...1655
Repair Instructions...1656
Antennas and Request Switches Removal and Installation...1656
Front Door (Driver and Passenger Side), Rear End Door / Trunk Lid Request Switch Inspection...1657
Steering Lock Unit Removal and Installation...1657
Steering Lock Unit Inspection...1657
Front Door Lock Switch Inspection...1658
Keyless Start Control Module Removal and Installation...1658
Remote Controller Inspection...1658
Replacement of Remote Controller Battery...1658
Registration Procedure for Remote Controller ID Code...1659
...
Suzuki SX4, SX4 Crossover Repair Service Manual 2006-2016
