Suzuki Swift, Swift Sport Repair Service Manual 1988-2010
Complete service repair manual with Electrical Wiring Diagrams for Suzuki Swift, Swift Sport, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki Swift, Swift Sport 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.
PRODUCT DETAILS:
Total Pages: 5,332 pages (2.3 GB)
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Suzuki Swift (RS413/RS415) Series Service Manual
Suzuki Swift Sport Service Manual
Suzuki Swift RS415 Service Manual
Suzuki Swift RS413/RS415/RS416 Service Manual
Suzuki Swift 1300GTi Service Manual
Suzuki Swift (a.k.a. Cultus 2. Generation, Geo Metro, Pontiac Firefly, Holden Barina, Subaru Justy, Chevrolet Swift) (SF310, SF413, SF416) Service Manual 1988-2003 (EN / DE / ES / FR)
Model A: SWIFT (RS413/RS415) 2004~
Model B: SWIFT (RS413D) 2005.05~
Model C: SWIFT (RS413/RS415/RS416/RS413D) 2006.06~
Model D: SWIFT (RS SERIES) 2007.10~
Language: English Italian Dutch French German Hungarian Spanish Slovak
MANUAL LIST...0
IMPORTANT...1
FOREWORD...3
TABLE OF CONTENTS...5
Precautions...7
Precautions...8
Precautions...8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System...8
General Precautions...10
Warning for Wheel (with tire) Removal...13
Precautions for Catalytic Converter...13
Precautions for Installing Mobile Communication Equipment...13
Precaution for CAN Communication System...14
Precautions for Electrical Circuit Service...14
Air Bag Warning...16
Air Bag System Service Warning...16
Fastener Caution...16
Suspension Caution...16
Wheels and Tires Caution...16
Brake Caution...17
Repair Instructions...17
Electrical Circuit Inspection Procedure...17
Intermittent and Poor Connection Inspection...19
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...27
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...36
Fuel Tank Inspection...37
PCV Valve Inspection...37
Fuel Evaporative Emission Control System Inspection...37
Brake Discs and Pads (Front) Inspection...37
Brake Drums and Shoes (Rear) Inspection...37
Brake Hoses and Pipes 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...39
Drive Shaft (Axle) Boots Inspection...40
Manual Transaxle Oil Inspection...40
Manual Transaxle Oil Replacement...40
Automatic Transaxle Fluid Level Inspection...40
Automatic Transaxle Fluid Replacement...41
Automatic Transaxle Fluid Cooler Hose Inspection...41
All Latches, Hinges and Locks Inspection...41
Air Conditioning Filter (If Equipped) Inspection...42
Air Conditioning 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
Precautions in Diagnosing Trouble...51
Precautions of ECM Circuit Inspection...52
Precautions of Electric Throttle Body System Calibration (For Automated Manual Transaxle Model)...52
General Description...52
Statement on Cleanliness and Care...52
Engine Diagnosis General Description...52
On-Board Diagnostic System Description...53
Engine and Emission Control System Description...55
CAN Communication System Description...55
Air Intake System Description...58
Description of Electric Throttle Body System (For Automated Manual Transaxle Model)...59
Description of Electric Throttle Body System Calibration (For Automated Manual Transaxle Model)...60
Electronic Control System Description...60
Engine and Emission Control Input / Output Table...67
Schematic and Routing Diagram...68
Engine and Emission Control System Diagram...68
Component Location...69
Electronic Control System Components Location...69
Diagnostic Information and Procedures...70
Engine and Emission Control System Check...70
Malfunction Indicator Lamp (MIL) Check...73
DTC Check...73
DTC Clearance...74
DTC Table...74
Fail-Safe Table...80
Scan Tool Data...82
Visual Inspection...88
Engine Basic Inspection...88
Engine Symptom Diagnosis...91
Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)...99
Malfunction Indicator Lamp Remains ON after Engine Starts...101
DTC P0010: Camshaft Position Actuator Circuit (For M15 Engine Model)...103
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For M15 Engine Model)...105
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)...107
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)...109
DTC P0101: Mass Air Flow Circuit Range / Performance...111
DTC P0102: Mass Air Flow Circuit Low Input...115
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...122
DTC P0108: Manifold Absolute Pressure Circuit High Input...124
DTC P0111: Intake Air Temperature Circuit Range / Performance...126
DTC P0112: Intake Air Temperature Sensor Circuit Low...129
DTC P0113: Intake Air Temperature Sensor Circuit High...132
DTC P0116: Engine Coolant Temperature Circuit Range / Performance...134
DTC P0117: Engine Coolant Temperature Circuit Low...137
DTC P0118: Engine Coolant Temperature Circuit High...139
DTC P0121: Throttle Position Sensor Circuit Range / Performance (For A/T and M/T Models)...142
DTC P0122: Throttle Position Sensor Circuit Low (For A/T and M/T Models)...146
DTC P0122: Throttle Position Sensor (Main) Circuit Low (For Automated Manual Transaxle Model)...149
DTC P0123: Throttle Position Sensor Circuit High (For A/T and M/T Models)...152
DTC P0123: Throttle Position Sensor (Main) Circuit High (For Automated Manual Transaxle Model)...155
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)...158
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)...161
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)...162
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)...165
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)...168
DTC P0171 / P0172: Fuel System Too Lean / Rich...170
DTC P0222: Throttle Position Sensor (Sub) Circuit Low (For Automated Manual Transaxle Model)...172
DTC P0223: Throttle Position Sensor (Sub) Circuit High (For Automated Manual Transaxle Model)...175
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...178
DTC P0327 / P0328: Knock Sensor Circuit Low / High...180
DTC P0335: Crankshaft Position (CKP) Sensor Circuit...182
DTC P0340: Camshaft Position (CMP) Sensor Circuit...184
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected...187
DTC P0403: Exhaust Gas Recirculation Control Circuit...190
DTC P0420: Catalyst System Efficiency below Threshold...192
DTC P0443: Evaporative Emission System Purge Control Valve Circuit...194
DTC P0462 / P0463: Fuel Level Sensor Circuit Low / High...196
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...197
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction...201
DTC P0505: Idle Air Control System (For A/T and M/T models)...204
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low...206
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High...208
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance (For Automated Manual Transaxle Model)...210
DTC P0616: Starter Relay Circuit Low...211
DTC P0617: Starter Relay Circuit High...212
DTC P1510: ECM Back-Up Power Supply Malfunction...214
DTC P1603: TCM Trouble Code Detected...215
DTC P1674: CAN Communication (Bus Off Error)...216
DTC P1675: CAN Communication (Transmission Error)...222
DTC P1676: CAN Communication (Reception Error for TCM (for A/T or Automated Manual Transaxle model))...227
DTC P1678: CAN Communication (Reception Error for BCM)...230
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance (For Automated Manual Transaxle Model)...233
DTC P2102: Throttle Actuator Control Motor Circuit Low (For Automated Manual Transaxle Model)...235
DTC P2103: Throttle Actuator Control Motor Circuit High (For Automated Manual Transaxle Model)...237
DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed (For Automated Manual Transaxle Model)...239
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance (For Automated Manual Transaxle Model)...240
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input (For Automated Manual Transaxle Model)...243
DTC P2123: Pedal Position Sensor (Main) Circuit High Input (For Automated Manual Transaxle Model)...246
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input (For Automated Manual Transaxle Model)...249
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input (For Automated Manual Transaxle Model)...252
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation (For Automated Manual Transaxle Model)...255
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation (For Automated Manual Transaxle Model)...258
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction...260
Inspection of ECM and Its Circuits...261
ECM Power and Ground Circuit Check...287
Fuel Injector Circuit Check...290
Fuel Pump and Its Circuit Check...292
Fuel Pressure Check...295
Idle Air Control System Check (For A/T and M/T models)...296
A/C System Circuits Check...298
Electric Load Signal Circuit Check...301
Radiator cooling fan Low Speed Control System Check...303
Radiator cooling fan High Speed Control System Check...305
Repair Instructions...308
Idle Speed / Idle Air Control (IAC) Duty Inspection (For A/T and M/T Models)...308
Special Tools and Equipment...308
Special Tool...308
Aux. Emission Control Devices...310
Diagnostic Information and Procedures...310
EGR System Inspection...310
Repair Instructions...310
EVAP Canister Purge Inspection...310
EVAP Canister Purge Valve and Its Circuit Inspection...310
Vacuum Passage Inspection...311
Vacuum Hose and Purge Valve Chamber Inspection...311
EVAP Canister Purge Valve Inspection...312
EVAP Canister Inspection...312
EGR Valve Removal and Installation...313
EGR Valve Inspection...313
PCV Hose Inspection...313
PCV Valve Inspection...313
Special Tools and Equipment...314
Special Tool...314
Engine Electrical Devices...315
Repair Instructions...315
Idle Air Control (IAC) Valve Operation Inspection (For A/T and M/T Models)...315
Idle Air Control (IAC) Valve On-Vehicle Inspection (For A/T and M/T Models)...315
Idle Air Control (IAC) Valve Removal and Installation (For A/T and M/T Models)...315
Engine Control Module (ECM) Removal and Installation...316
Manifold Absolute Pressure (MAP) Sensor Inspection...316
Throttle Position (TP) Sensor On-Vehicle Inspection (For A/T and M/T Models)...317
Throttle Position (TP) Sensor Removal and Installation (For A/T and M/T Models)...317
Electric Throttle Body Assembly On-Vehicle Inspection (For Automated Manual Transaxle Model)...318
Electric Throttle Body System Calibration (For Automated Manual Transaxle Model)...320
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection (For Automated Manual Transaxle Model)...320
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation (For Automated Manual Transaxle Model)...321
Accelerator Pedal Position (APP) Sensor Assembly Inspection (For Automated Manual Transaxle Model)...321
Engine Coolant Temperature (ECT) Sensor Removal and Installation...322
Engine Coolant Temperature (ECT) Sensor Inspection...322
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection...323
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation...323
Camshaft Position (CMP) Sensor Removal and Installation...323
Camshaft Position (CMP) Sensor Inspection...324
Crankshaft Position (CKP) Sensor Removal and Installation...324
Crankshaft Position (CKP) Sensor Inspection...325
Vehicle Speed Sensor (VSS) Inspection (M/T and Automated Manual Transaxle model)...325
Knock Sensor Removal and Installation...326
Main Relay, Fuel Pump Relay, Starting Motor Control Relay and Throttle Actuator Control Relay Inspection...326
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection...326
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation...327
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection...328
Specifications...329
Tightening Torque Specifications...329
Special Tools and Equipment...329
Special Tool...329
Engine Mechanical...330
General Description...330
Engine Construction Description...330
Camshaft Position Control (VVT Variable Valve Timing) System Description...331
Diagnostic Information and Procedures...334
Compression Check...334
Engine Vacuum Check...335
Valve Lash (Clearance) Inspection...335
Repair Instructions...338
Air Cleaner Element Removal and Installation...338
Air Cleaner Element Inspection and Cleaning...338
Cylinder Head Cover Removal and Installation...338
Accelerator Cable Adjustment (For A/T and M/T Models)...340
Throttle Body Components...341
Throttle Body On-Vehicle Inspection...341
Throttle Body Removal and Installation (For A/T and M/T Models)...341
Electric Throttle Body Assembly Removal and Installation (For Automated Manual Transaxle Model)...342
Throttle Body Cleaning...343
Throttle Body and Intake Manifold Components...344
Intake Manifold Removal and Installation...344
Engine Mountings Components...346
Engine Assembly Removal and Installation...347
Timing Chain Cover Components...351
Timing Chain Cover Removal and Installation...352
Timing Chain Cover Inspection...354
Oil Control Valve Removal and Installation (For Engine with VVT)...354
Oil Control Valve Inspection (For Engine with VVT)...355
Timing Chain and Chain Tensioner Components...355
Timing Chain and Chain Tensioner Removal and Installation...356
Timing Chain and Chain Tensioner Inspection...359
Camshaft, Tappet and Shim Components...361
Camshaft, Tappet and Shim Removal and Installation...362
Camshaft, Tappet and Shim Inspection...364
Valves and Cylinder Head Components...367
Valves and Cylinder Head Removal and Installation...367
Valves and Cylinder Head Disassembly and Assembly...369
Valves and Valve Guides Inspection...372
Cylinder Head Inspection...374
Valve Spring Inspection...375
Pistons, Piston Rings, Connecting Rods and Cylinders Components...376
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation...376
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly...377
Cylinders, Pistons and Piston Rings Inspection...378
Piston Pins and Connecting Rods Inspection...380
Crank Pin and Connecting Rod Bearings Inspection...381
Main Bearings, Crankshaft and Cylinder Block Components...385
Main Bearings, Crankshaft and Cylinder Block Removal and Installation...386
Crankshaft Inspection...388
Main Bearings Inspection...389
Sensor Plate Inspection...395
Rear Oil Seal Inspection...395
Flywheel Inspection...395
Cylinder Block Inspection...395
Specifications...396
Tightening Torque Specifications...396
Special Tools and Equipment...397
Recommended Service Material...397
Special Tool...397
Engine Lubrication System...399
General Description...399
Engine Lubrication Description...399
Diagnostic Information and Procedures...401
Oil Pressure Check...401
Repair Instructions...402
Oil Pan and Oil Pump Strainer Components...402
Oil Pan and Oil Pump Strainer Removal and Installation...403
Oil Pan and Oil Pump Strainer Cleaning...404
Oil Pump Components...405
Oil Pump Removal and Installation...405
Oil Pump Disassembly and Reassembly...405
Oil Pump Inspection...406
Specifications...407
Tightening Torque Specifications...407
Special Tools and Equipment...408
Recommended Service Material...408
Special Tool...408
Engine Cooling System...409
General Description...409
Cooling System Description...409
Coolant Description...409
Schematic and Routing Diagram...410
Coolant Circulation...410
Diagnostic Information and Procedures...411
Engine Cooling Symptom Diagnosis...411
Repair Instructions...412
Cooling System Components...412
Coolant Level Check...413
Engine Cooling System Inspection and Cleaning...413
Cooling System Draining...413
Cooling System Flush and Refill...414
Cooling Water Pipes or Hoses Removal and Installation...415
Thermostat Removal and Installation...415
Thermostat Inspection...415
Radiator Cooling Fan Motor On-Vehicle Inspection...416
Radiator Cooling Fan Relay Inspection...416
Radiator Cooling Fan Removal and Installation...416
Radiator On-Vehicle Inspection and Cleaning...417
Radiator Removal and Installation...417
Water Pump / Generator Drive Belt Tension Inspection and Adjustment...417
Water Pump / Generator Drive Belt Removal and Installation...418
Water Pump Removal and Installation...419
Water Pump Inspection...419
Specifications...420
Tightening Torque Specifications...420
Special Tools and Equipment...420
Recommended Service Material...420
Fuel System...421
Precautions...421
Precautions on Fuel System Service...421
General Description...421
Fuel System Description...421
Fuel Delivery System Description...421
Fuel Pump Description...422
Schematic and Routing Diagram...422
Fuel Delivery System Diagram...422
Diagnostic Information and Procedures...422
Fuel Pressure Inspection...422
Fuel Cut Operation Inspection...423
Repair Instructions...424
Fuel System Components...424
Fuel Hose Disconnecting and Reconnecting...425
Fuel Pressure Relief Procedure...427
Fuel Leakage Check Procedure...427
Fuel Lines On-Vehicle Inspection...427
Fuel Pipe Removal and Installation...427
Fuel Injector On-Vehicle Inspection...428
Fuel Injector Removal and Installation...428
Fuel Injector Inspection...429
Fuel Filler Cap Inspection...430
Fuel Tank Removal and Installation...430
Fuel Tank Inspection...432
Fuel Tank Purging Procedure...432
Fuel Pump On-Vehicle Inspection...432
Fuel Pump Assembly Removal and Installation...433
Fuel Pump Inspection...434
Specifications...434
Tightening Torque Specifications...434
Special Tools and Equipment...435
Special Tool...435
Ignition System...436
General Description...436
Ignition System Construction...436
Schematic and Routing Diagram...437
Ignition System Wiring Circuit Diagram...437
Component Location...438
Ignition System Components Location...438
Diagnostic Information and Procedures...438
Ignition System Symptom Diagnosis...438
Reference Waveform of Ignition System...439
Ignition System Check...439
Ignition Spark Test...440
Repair Instructions...441
High-Tension Cord Removal and Installation...441
High-Tension Cord Inspection...441
Spark Plug Removal and Installation...441
Spark Plug Inspection...442
Ignition Coil Assembly (Including ignitor) Removal and Installation...442
Ignition Coil Assembly (Including ignitor) Inspection...443
Ignition Timing Inspection...443
Specifications...444
Tightening Torque Specifications...444
Special Tools and Equipment...444
Special Tool...444
Starting System...445
Schematic and Routing Diagram...445
Cranking System Circuit Diagram...445
Diagnostic Information and Procedures...445
Cranking System Symptom Diagnosis...445
Cranking System Test...447
Repair Instructions...448
Starting Motor Dismounting and Remounting...448
Starting Motor Components...449
Starting Motor Inspection...451
Specifications...454
Cranking System Specifications...454
Tightening Torque Specifications...455
Special Tools and Equipment...455
Recommended Service Material...455
Charging System...456
General Description...456
Battery Description...456
Generator Description...457
Diagnostic Information and Procedures...458
Battery Inspection...458
Generator Symptom Diagnosis...458
Generator Test (Undercharged Battery Check)...459
Generator Test (Overcharged Battery Check)...459
Repair Instructions...460
Jump Starting in Case of Emergency...460
Battery Dismounting and Remounting...460
Generator Dismounting and Remounting...461
Generator Components...461
Generator Inspection...462
Specifications...463
Charging System Specifications...463
Tightening Torque Specifications...464
Exhaust System...465
General Description...465
Exhaust System Description...465
Diagnostic Information and Procedures...465
Exhaust System Check...465
Repair Instructions...466
Exhaust System Components...466
Exhaust Manifold Removal and Installation...467
Exhaust Pipe and Muffler Removal and Installation...468
Specifications...469
Tightening Torque Specifications...469
Suspension...471
Precautions...473
Precautions...473
Precautions on Suspension...473
Suspension General Diagnosis...474
Diagnostic Information and Procedures...474
Suspension, Wheels and Tires Symptom Diagnosis...474
Specifications...476
Wheel Alignment Specifications...476
Front Suspension...477
General Description...477
Front Suspension Construction...477
Front Wheel Alignment Construction...478
Repair Instructions...478
Front Wheel Alignment Inspection and Adjustment...478
Front Strut Assembly Components...480
Front Strut Assembly Removal and Installation...480
Front Strut Assembly Disassembly and Assembly...482
Front Strut Assembly Check...483
Front Wheel Hub and Steering Knuckle Components...484
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation...484
Front Wheel Hub, Disc, Nut and Bearing Check...488
Suspension Control Arm / Bushing Removal and Installation...488
Suspension Control Arm / Bushing Disassembly and Assembly...489
Suspension Control Arm / Steering Knuckle Check...490
Suspension Control Arm Bushing Check...490
Suspension Control Arm Joint Check...490
Front Suspension Frame, Stabilizer Bar and/or Bushings Components...491
Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation...491
Front Suspension Frame Check...494
Front Stabilizer Bar, Bushing and/or Joint Check...495
Front Suspension Fasteners Check...495
Specifications...495
Tightening Torque Specifications...495
Special Tools and Equipment...496
Special Tool...496
Rear Suspension...498
General Description...498
Rear Suspension Construction...498
Repair Instructions...499
Rear Shock Absorber Removal and Installation...499
Rear Shock Absorber Inspection...500
Rear Shock Absorber Bush Removal and Installation...500
Rear Shock Absorber Bush Inspection...501
Coil Spring Removal and Installation...501
Spring Upper Seat / Spring Lower Seat Inspection...502
Spring Upper Seat and Lower Seat Removal and Installation...502
Rear Axle Removal and Installation...503
Trailing Arm, Rear Axle and Coil Spring Inspection...506
Rear Axle Bush Inspection...506
Wheel Bearing and Wheel Stud Bolt Removal and Installation...507
Rear Wheel Disc, Nut and Bearing Inspection...507
Spindle Removal and Installation...508
Spindle Inspection...509
Rear Suspension Fasteners Inspection...509
Specifications...510
Tightening Torque Specifications...510
Special Tools and Equipment...510
Special Tool...510
Wheels and Tires...511
General Description...511
Tires Description...511
Wheels Description...512
Irregular and/or Premature Wear Description...512
Wear Indicators Description...513
Radial Tire Waddle Description...513
Radial Tire Lead / Pull Description...514
Balancing Wheels Description...514
Repair Instructions...515
General Balance Procedures...515
Tire Rotation...515
Wheel Removal and Installation...515
Tire Mounting and Dismounting...516
Tire Repair...516
Specifications...517
Wheels and Tires Specifications...517
Tightening Torque Specifications...517
Driveline / Axle...519
Precautions...520
Precautions...520
Precautions for Driveline / Axle...520
Drive Shaft / Axle...521
General Description...521
Front Drive Shaft Construction...521
Component Location...521
Front Drive Shaft Assembly Components Location...521
Diagnostic Information and Procedures...522
Front Drive Shaft Symptom Diagnosis...522
Repair Instructions...522
Front Drive Shaft Components...522
Front Drive Shaft Assembly On-Vehicle Inspection...524
Front Drive Shaft Assembly Removal and Installation...524
Front Drive Shaft Disassembly and Assembly...525
Center Shaft and Center Bearing Support Disassembly and Assembly...528
Front Drive Shaft Inspection...530
Specifications...531
Tightening Torque Specifications...531
Special Tools and Equipment...531
Recommended Service Material...531
Special Tool...531
Brakes...533
Precautions...535
Precautions...535
Precautions for Brakes...535
Brake Control System and Diagnosis...536
Precautions...536
Precautions on Brake...536
General Description...536
Brakes Construction...536
Front Brake Hose / Pipe Construction...537
Rear Brake Hose / Pipe Construction...538
Diagnostic Information and Procedures...538
Brakes Diagnosis Note...538
Brakes Symptom Diagnosis...539
Repair Instructions...541
Brake Pedal Free Height Inspection...541
Brake Pedal Play Inspection...541
Excessive Pedal Travel Inspection...541
Master Cylinder and Brake Fluid Level Inspection...542
Stop Light Switch Adjustment...542
Air Bleeding of Brake System...542
Front Brake Hose / Pipe Removal and Installation...543
Rear Brake Hose / Pipe Removal and Installation...544
Brake Hose and Pipe Inspection...544
Master Cylinder Components...545
Master Cylinder Assembly Removal and Installation...545
Master Cylinder Reservoir Removal and Installation...547
Master Cylinder Assembly Inspection...548
Brake Booster Components...548
Booster Operation Inspection...548
Brake Booster Removal and Installation...549
Brake Booster Inspection...550
Specifications...551
Tightening Torque Specifications...551
Special Tools and Equipment...551
Recommended Service Material...551
Front Brakes...552
Repair Instructions...552
Front Disc Brake Components...552
Front Disc Brake Pad On-Vehicle Inspection...552
Front Disc Brake Pad Removal and Installation...553
Front Disc Brake Pad Inspection...554
Front Disc Brake Caliper Removal and Installation...554
Front Disc Brake Caliper Disassembly and Assembly...555
Front Disc Brake Caliper Inspection...557
Front Brake Disc Removal and Installation...557
Front Brake Disc Inspection...558
Specifications...558
Tightening Torque Specifications...558
Special Tools and Equipment...559
Recommended Service Material...559
Special Tool...559
Rear Brakes...560
Repair Instructions...560
Rear Drum Brake Components...560
Rear Brake Drum Removal and Installation...560
Rear Brake Drum and Shoe Inspection...562
Rear Brake Shoe On-Vehicle Inspection...562
ABS Sensor Ring Removal and Installation (If Equipped)...563
ABS Sensor Ring Inspection...563
Rear Brake Shoe Removal and Installation...563
Rear Brake Shoe Inspection...564
Wheel Cylinder Removal and Installation...564
Wheel Cylinder Inspection...565
Brake Back Plate Removal and Installation...565
Specifications...567
Tightening Torque Specifications...567
Special Tools and Equipment...567
Recommended Service Material...567
Special Tool...567
Parking Brake...568
General Description...568
Parking Brake Cable Construction...568
Repair Instructions...569
Parking Brake Inspection and Adjustment...569
Parking Brake Cable Removal and Installation...569
Parking Brake Lever Removal and Installation...570
Specifications...571
Tightening Torque Specifications...571
ABS...572
Precautions...572
Precautions in Diagnosing Troubles...572
Precautions in On-Vehicle Service...572
General Description...572
ABS Description...572
ABS Hydraulic Unit / Control Module Assembly Description...573
Schematic and Routing Diagram...574
ABS Schematic...574
ABS Wiring Circuit Diagram...575
Component Location...576
ABS Components Location...576
Diagnostic Information and Procedures...577
ABS Check...577
ABS Warning Lamp Check...579
EBD Warning Lamp (Brake Warning Lamp) Check...579
DTC Check...579
DTC Table...580
DTC Clearance...580
Scan Tool Data...580
ABS Warning Lamp Does Not Come ON at Ignition Switch ON...581
ABS Warning Lamp Comes ON Steady...582
ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON...584
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady...584
Serial Data Link Circuit Check...585
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring...587
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...589
DTC C1057: Power Source Circuit...590
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit...591
DTC C1063: Solenoid Valve Power Supply Driver Circuit...592
DTC C1071: ABS Control Module...593
Repair Instructions...594
ABS Hydraulic Unit Operation Check...594
ABS Hydraulic Unit / Control Module Assembly Components...595
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...595
ABS Hydraulic Unit / Control Module Assembly Removal and Installation...595
Front Wheel Speed Sensor On-Vehicle Inspection...597
Front Wheel Speed Sensor Removal and Installation...597
Front Wheel Speed Sensor Inspection...598
Rear Wheel Speed Sensor On-Vehicle Inspection...598
Rear Wheel Speed Sensor Removal and Installation...599
Rear Wheel Speed Sensor Inspection...600
Front Wheel Speed Sensor Ring On-Vehicle Inspection...600
Front Wheel Speed Sensor Ring Removal and Installation...600
Rear Wheel Speed Sensor Ring On-Vehicle Inspection...600
Rear Wheel Speed Sensor Ring Removal and Installation...601
Specifications...601
Tightening Torque Specifications...601
Special Tools and Equipment...601
Special Tool...601
Transmission / Transaxle...603
Precautions...608
Precautions...608
Precautions on Transmission / Transaxle...608
Automatic Transmission...609
Precautions...609
Precautions in Diagnosing Trouble...609
Precautions for Disassembly and Reassembly...609
General Description...611
A/T Description...611
Clutch / Brake / Planetary Gear Function of Automatic Transaxle...613
Table of Component Operation...614
A/T Diagnosis General Description...614
On-Board Diagnostic System Description...615
CAN Communication System Description...615
Schematic and Routing Diagram...617
Transmission Control Module (TCM) Wiring Diagram...617
Automatic Gear Shift Table...619
Component Location...620
Electronic Shift Control System Components Location...620
Diagnostic Information and Procedures...622
A/T System Check...622
Visual Inspection...624
Malfunction Indicator Lamp (MIL) Check...625
DTC Table...625
DTC Check...626
DTC Clearance...627
Fail-Safe Table...627
Scan Tool Data...630
A/T Basic Check...633
Road Test...634
Manual Road Test...636
Engine Brake Test...637
Stall Test...637
Time Lag Test...638
Line Pressure Test...638
“P” Range Test...639
A/T Symptom Diagnosis...640
No Gear Shift to 4th gear...647
No Lock-Up Occurs...648
DTC P0705: Transmission Range Sensor Circuit Malfunction...649
DTC P0707: Transmission Range Sensor Circuit Low...651
DTC P0712: Transmission Fluid Temperature Sensor Circuit Low...653
DTC P0713: Transmission Fluid Temperature Sensor Circuit High...654
DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction...655
DTC P0722: Output Speed Sensor (VSS) Circuit No Signal...657
DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON...659
DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction...660
DTC P0787: Shift / Timing Solenoid Control Circuit Low...662
DTC P0788: Shift / Timing Solenoid Control Circuit High...664
DTC P0962: Pressure Control Solenoid Control Circuit Low...666
DTC P0963: Pressure Control Solenoid Control Circuit High...668
DTC P0973 / P0976: Shift Solenoid-A (No.1) Control Circuit Low / Shift Solenoid-B (No.2) Control Circuit Low...670
DTC P0974 / P0977: Shift Solenoid-A (No.1) / Shift Solenoid-B (No.2) Control Circuit High...672
DTC P1702: Internal Control Module Memory Check Sum Error...674
DTC P1703: Can Invalid Data - TCM...674
DTC P1723: Range Select Switch Malfunction...674
DTC P1774: Control Module Communication Bus Off...676
DTC P1775: High Speed CAN Communication Bus Off (Transmission Error)...681
DTC P1777: TCM Lost Communication with ECM (Reception Error)...684
DTC P1778: TCM Lost Communication with BCM (Reception Error)...687
DTC P1878: Torque Converter Clutch Shudder...690
DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High...690
DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low...693
Inspection of TCM and Its Circuits...695
TCM Power and Ground Circuit Check...699
Brake Interlock System Inspection...700
Repair Instructions...701
Learning Control Initialization...701
A/T Fluid Level Check...701
A/T Fluid Change...702
Selector Lever Components...702
Select Lever Assembly Installation...702
Select Lever Knob Installation...703
Selector Lever Inspection...703
Select Cable Components...703
Select Cable Removal and Installation...704
Select Cable Adjustment...704
Transmission Range Sensor (Shift Switch) Inspection and Adjustment...704
Output Shaft Speed Sensor (VSS) Removal and Installation...705
Output Shaft Speed Sensor (VSS) Inspection...705
Input Shaft Speed Sensor Removal and Installation...706
Input Shaft Speed Sensor Inspection...706
Transmission Fluid Temperature Sensor Removal and Installation...706
Transmission Fluid Temperature Sensor Inspection...707
“3” Position Switch Inspection...707
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation...708
Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection...709
Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...711
Pressure Control Solenoid Valve Inspection...711
Transmission Control Module (TCM) Removal and Installation...712
A/T Relay Inspection...713
Differential Side Oil Seal Replacement...713
Shift Lock Solenoid Inspection...714
Shift Lock Solenoid Replacement...714
Key Interlock Cable Removal and Installation...715
A/T Fluid Cooler Hoses Replacement...716
Automatic Transaxle Unit Components...716
Automatic Transaxle Unit Dismounting and Remounting...717
Automatic Transaxle Assembly Components...719
Automatic Transaxle Unit Disassembly...720
Oil Pump Assembly Components...731
Oil Pump Assembly Disassembly and Reassembly...732
Oil Pump Assembly Inspection...733
Direct Clutch Assembly Components...734
Direct Clutch Assembly Preliminary Check...734
Direct Clutch Assembly Disassembly and Reassembly...735
Direct Clutch Assembly Inspection...737
Forward and Reverse Clutch Assembly Components...738
Forward and Reverse Clutch Assembly Preliminary Check...738
Forward and Reverse Clutch Assembly Disassembly and Reassembly...739
Forward and Reverse Clutch Assembly Inspection...742
2nd Brake Piston Assembly Components...743
2nd Brake Piston Assembly Disassembly and Reassembly...743
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components...744
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly...745
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection...746
Countershaft Assembly Components...747
Countershaft Assembly Disassembly and Reassembly...747
Valve Body Assembly Components...748
Valve Body Assembly Disassembly and Reassembly...749
Differential Assembly Components...750
Differential Assembly Disassembly and Reassembly...750
Differential Assembly Inspection...752
Torque Converter Housing Disassembly and Reassembly...752
Transaxle Case Disassembly and Reassembly...754
Automatic Transaxle Unit Inspection and Adjustment...756
Automatic Transaxle Unit Assembly...758
Specifications...774
Tightening Torque Specifications...774
Special Tools and Equipment...775
Recommended Service Material...775
Special Tool...775
Manual Transmission...778
For M13 Engine Model...778
General Description...778
Manual Transaxle Construction and Servicing...778
Diagnostic Information and Procedures...780
Manual Transaxle Symptom Diagnosis...780
Repair Instructions...780
Manual Transaxle Oil Change...780
Differential Side Oil Seal Replacement...781
Gear Shift Control Lever and Cable Components...782
Gear Shift Control Lever and Cable Removal and Installation...783
Gear Select Control Cable Adjustment...783
Vehicle Speed Sensor (VSS) Removal and Installation...784
Back Up Lamp Switch Removal and Installation...784
Back Up Lamp Switch Inspection...785
Manual Transaxle Unit Components...785
Manual Transaxle Unit Dismounting and Remounting...786
Gear Shift and Select Shaft Assembly Components...788
Gear Shift and Select Shaft Assembly Removal and Installation...789
Gear Shift and Select Shaft Disassembly and Assembly...790
Manual Transaxle Assembly Components...791
Fifth Gear Disassembly and Assembly...792
Manual Transaxle Assembly Disassembly and Reassembly...795
Transaxle Right Case Disassembly and Assembly...799
Transaxle Left Case Disassembly and Assembly...800
Input Shaft and Countershaft Components...801
Input Shaft Assembly Disassembly and Reassembly...802
Countershaft Assembly Disassembly and Reassembly...804
Synchronizer Parts Inspection...807
Gear Shift Shaft Components...807
5th and Reverse Gear Shift Shafts Disassembly and Assembly...807
Gear Shift Shaft and Fork Inspection...808
Differential Components...808
Differential Disassembly and Assembly...809
Specifications...811
Tightening Torque Specifications...811
Special Tools and Equipment...811
Recommended Service Material...811
Special Tool...812
For M15 Engine Model...814
General Description...814
Manual Transaxle Construction and Servicing...814
Diagnostic Information and Procedures...816
Manual Transaxle Symptom Diagnosis...816
Repair Instructions...816
Manual Transaxle Oil Change...816
Differential Side Oil Seal Replacement...817
Gear Shift Control Lever and Cable Components...818
Gear Shift Control Lever and Cable Removal and Installation...819
Gear Select Control Cable Adjustment...819
Vehicle Speed Sensor (VSS) Removal and Installation...820
Back Up Lamp Switch Removal and Installation...820
Back Up Lamp Switch Inspection...821
Manual Transaxle Unit Components...821
Manual Transaxle Unit Dismounting and Remounting...822
Gear Shift and Select Shaft Assembly Components...824
Gear Shift and Select Shaft Assembly Removal and Installation...824
Gear Shift and Select Shaft Disassembly and Assembly...825
Manual Transaxle Assembly Components...826
Fifth Gear Disassembly and Assembly...827
Manual Transaxle Assembly Disassembly and Reassembly...829
Transaxle Right Case Disassembly and Assembly...835
Transaxle Left Case Disassembly and Assembly...836
Input Shaft and Countershaft Components...837
Input Shaft Assembly Disassembly and Reassembly...838
Countershaft Assembly Disassembly and Reassembly...840
Synchronizer Parts Inspection...843
Gear Shift Shaft Components...843
5th and Reverse Gear Shift Shafts Disassembly and Assembly...844
Gear Shift Shaft and Fork Inspection...844
Differential Components...845
Differential Disassembly and Assembly...845
Specifications...847
Tightening Torque Specifications...847
Special Tools and Equipment...848
Recommended Service Material...848
Special Tool...848
Clutch...851
General Description...851
Clutch Construction...851
Diagnostic Information and Procedures...852
Clutch System Symptom Diagnosis...852
Repair Instructions...852
Clutch Pedal Inspection...852
Clutch Fluid Level Inspection...853
Air Bleeding of Clutch System...853
Clutch Fluid Pipe and Hose Components...854
Clutch Fluid Pipe Removal and Installation...855
Clutch Fluid Pipe Inspection...855
Clutch Master Cylinder Removal and Installation...855
Clutch Operating Cylinder Removal and Installation...856
Clutch Pedal and Clutch Pedal Bracket Components...857
Clutch Cover, Clutch Disc and Flywheel Components...857
Clutch Cover, Clutch Disc and Flywheel Removal and Installation...858
Clutch Cover, Clutch Disc and Flywheel Inspection...859
Clutch Release System Removal and Installation...860
Clutch Release System Inspection...861
Specifications...862
Tightening Torque Specifications...862
Special Tools and Equipment...862
Recommended Service Material...862
Special Tool...863
Automated Manual Transaxle...864
Precautions...864
Precautions in Diagnosing Trouble...864
General Description...864
Automated Manual Transaxle Description...864
Automated Manual Transaxle Diagnosis General Description...867
On-Board Diagnostic System Description...867
CAN Communication System Description...868
Schematic and Routing Diagram...868
TCM (Automated Manual Transaxle) Wiring Diagram...868
Automatic Gear Shift Table...870
Component Location...872
Electronic Shift Control System Components Location...872
Diagnostic Information and Procedures...873
Automated Manual Transaxle System Check...873
Visual Inspection...876
Malfunction Indicator Lamp (MIL) Check...877
Automated Manual Transaxle Warning Lamp Check...877
DTC Table...877
DTC Check...879
DTC Clearance...880
Fail-Safe Table...881
Scan Tool Data...882
Automated Manual Transaxle Symptom Diagnosis...885
Automated Manual Transaxle Warning Lamp Does Not Come ON at Ignition Switch ON...889
Automated Manual Transaxle Warning Lamp Remains ON at Ignition Switch ON...891
Starting Motor Control Relay Circuit Check...892
DTC P0705: Transmission Range Sensor Circuit Malfunction...894
DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction...896
DTC P0722: Output Speed Sensor Circuit...898
DTC P0727: Engine Speed Input Circuit...899
DTC P0807: Clutch Position Sensor Circuit Low...900
DTC P0808: Clutch Position Sensor Circuit High...902
DTC P0810: Clutch Position Control Error...904
DTC P0902 / P0903: Clutch Actuator Circuit Low / High...906
DTC P0906: Gate Select Position Circuit Low...908
DTC P0907: Gate Select Position Circuit High...910
DTC P0909: Gate Select Control Error...912
DTC P0912 / P0913: Gate Select Actuator Circuit Low / High...914
DTC P0916: Gear Shift Position Circuit Low...916
DTC P0917: Gear Shift Position Circuit High...918
DTC P0919: Gear Shift Position Control Error...920
DTC P1703: CAN Invalid Data - Automated Manual Transaxle Control...922
DTC P1774: Control Module Communication Bus Off...923
DTC P1777: TCM (Automated Manual Transaxle) Lost Communication with ECM (Reception Error)...926
DTC P1778: TCM (Automated Manual Transaxle) Lost Communication with BCM (Reception Error)...928
DTC P1840: TCM (Automated Manual Transaxle) System Voltage...930
DTC P1841 / P1842: CPU Malfunction / TCM (Automated Manual Transaxle) Internal Module Keep Alive Memory Error...931
DTC P1843: Brake Switch “A/B” Error...931
DTC P1845: Warning Buzzer Circuit Malfunction...933
DTC P1846: Reverse Input Circuit No Signal...933
DTC P1847: Reverse Input Circuit Short...935
DTC P1848: Motor Relay Circuit Low...936
DTC P1849: Motor Relay Circuit High...938
DTC P1856: Clutch Position Sensor Circuit “B” Low...939
DTC P1857: Clutch Position Sensor Circuit “B” High...941
DTC P1858: Gate Select Position Circuit “B” Low...943
DTC P1859: Gate Select Position Circuit “B” High...944
DTC P1880 / P1881: Gear Shift Actuator Circuit Low / High...946
DTC P1882: Gear Shift Position Circuit “B” Low...948
DTC P1883: Gear Shift Position Circuit “B” High...950
DTC P1900: Clutch Position Sensor “A/B” Correlation...951
DTC P1901: Gear Shift Position Sensor “A/B” Correlation...953
DTC P1960: Gate Select Position Sensor “A/B” Correlation...955
TCM (Automated Manual Transaxle) Power and Ground Circuit Check...956
Inspection of TCM (Automated Manual Transaxle) and Its Circuits...957
Repair Instructions...965
TCM (Automated Manual Transaxle) Initialization...965
Clutch Position Control...965
Automated Manual Transaxle Oil Change...965
Differential Side Oil Seal Replacement...966
Shift Selector Components...967
Shift Selector Assembly Removal and Installation...967
Shift Selector Assembly Disassembly and Reassembly...968
Shift Selector Inspection...970
Clutch Stroke Sensor Removal and Installation...971
Clutch Stroke Sensor Inspection...972
Clutch Actuator Removal and Installation...972
Clutch Actuator Inspection...973
Shift and Select Stroke Sensor Removal and Installation...974
Shift Stroke Sensor and Select Stroke Sensor Inspection...974
Shift and Select Actuator Removal and Installation...975
Shift and Select Actuator Inspection...976
Input Shaft Speed Sensor Removal and Installation...977
Input Shaft Speed Sensor Inspection...977
Neutral Start Switch Removal and Installation...977
Neutral Start Switch Inspection...978
Back Up Lamp Switch Removal and Installation...978
Back Up Lamp Switch Inspection...978
Output Shaft Speed Sensor (VSS) Removal and Installation...978
Transmission Control Module (TCM) Removal and Installation...979
Motor Relay Inspection...979
Automated Manual Transaxle Unit Components...980
Automated Manual Transaxle Unit Dismounting and Remounting...980
Automated Manual Transaxle Assembly Components...982
Automated Manual Transaxle Assembly Disassembly and Reassembly...983
Left Case Assembly Disassembly and Reassembly...985
Countershaft Tapered Roller Bearing Preload Adjustment...986
Input Shaft Bearing Shim Adjustment...988
Differential Left Side Bearing Preload Adjustment...988
Right Case Assembly Disassembly and Reassembly...989
Input Shaft Assembly Components...991
Input Shaft Assembly Disassembly and Reassembly...991
Input Shaft Assembly Inspection...994
Countershaft Components...996
Countershaft Assembly Disassembly and Reassembly...997
Countershaft Assembly Inspection...999
Gear Shift Shaft Components...1001
Gear Shift Shaft Disassembly and Reassembly...1001
Gear Shift Shaft Inspection...1003
Differential Components...1003
Differential Assembly Disassembly and Reassembly...1003
Clutch Cover and Clutch Disc Components...1006
Clutch Cover and Clutch Disc Removal and Installation...1006
Clutch Release System Component Removal and Installation...1007
Clutch Inspection...1008
Specifications...1009
Tightening Torque Specifications...1009
Special Tools and Equipment...1010
Recommended Service Material...1010
Special Tool...1010
Steering...1013
Precautions...1015
Precautions...1015
Precautions on Steering...1015
Steering General Diagnosis...1016
Precautions...1016
Precautions for Steering Diagnosis...1016
Diagnostic Information and Procedures...1016
Steering Symptom Diagnosis...1016
Steering Wheel and Column...1018
Precautions...1018
Service Precautions of Steering Wheel and Column...1018
Diagnostic Information and Procedures...1018
Checking Steering Column for Accident Damage...1018
Repair Instructions...1019
Steering Wheel and Column Construction...1019
Steering Wheel Removal and Installation...1020
Contact Coil Cable Assembly Removal and Installation...1021
Centering Contact Coil Cable Assembly...1021
Contact Coil Cable Assembly Inspection...1022
Steering Column Removal and Installation...1022
Steering Column Inspection...1024
Steering Lock Assembly (Ignition Switch) Removal and Installation...1024
Steering Lower Shaft Removal and Installation...1025
Specifications...1027
Tightening Torque Specifications...1027
Special Tools and Equipment...1027
Special Tool...1027
Power Assisted Steering System...1028
Precautions...1028
Steering System Note...1028
Precautions in Diagnosing Troubles...1028
General Description...1028
P/S System Description...1028
EPS Diagnosis General Description...1029
On-Board Diagnostic System Description...1029
Schematic and Routing Diagram...1030
EPS System Wiring Circuit Diagram...1030
Diagnostic Information and Procedures...1031
EPS System Check...1031
“EPS” Warning Lamp Check...1032
DTC Check...1033
DTC Clearance...1033
DTC Table...1033
Scan Tool Data...1035
P/S System Symptom Diagnosis...1035
Serial Data Link Circuit Check...1036
“EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stops...1038
“EPS” Warning Lamp Comes ON Steady and Engine Start...1040
DTC C1113 / C1117 / C1118: Torque Sensor Circuit Failure...1041
DTC C1114: Torque Sensor 5 V Power Supply Circuit Failure...1042
DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure...1044
DTC C1121 / C1123 / C1124: VSS Circuit Failure...1046
DTC C1122: Engine Speed Signal Circuit Failure...1048
DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure...1049
DTC C1153: P/S Control Module Power Supply Circuit Voltage Low...1050
DTC C1155: P/S Control Module Failure...1052
Inspection of P/S Control Module and Its Circuits...1052
Steering Wheel Play Check...1054
Steering Force Check...1055
Repair Instructions...1056
Steering Gear Case Assembly Components...1056
Tie-Rod End Boot On-Vehicle Inspection...1057
Tie-Rod End Removal and Installation...1057
Tie-Rod End Inspection...1058
Steering Shaft Joint On-Vehicle Inspection...1058
Steering Gear Case Assembly Removal and Installation...1058
Steering Rack Boot Inspection...1060
Tie-Rod / Rack Boot Removal and Installation...1060
Steering Rack Plunger Removal and Installation...1061
Steering Rack Plunger Inspection...1062
P/S Control Module Removal and Installation...1062
Torque Sensor Inspection...1063
Motor Assembly Inspection...1063
Specifications...1064
Tightening Torque Specifications...1064
Special Tools and Equipment...1064
Recommended Service Material...1064
Special Tool...1064
HVAC...1067
Precautions...1068
Precautions...1068
Precautions on HVAC...1068
Heater and Ventilation...1069
General Description...1069
Heater and Ventilation Construction...1069
Schematic and Routing Diagram...1070
Heater and Ventilation Wiring Circuit Diagram...1070
Diagnostic Information and Procedures...1071
Heater and Ventilation Symptom Diagnosis...1071
Repair Instructions...1072
HVAC Unit Components...1072
HVAC Unit Removal and Installation...1073
Blower Motor Removal and Installation...1073
Blower Motor Inspection...1073
Blower Motor Resistor Removal and Installation...1074
Blower Motor Resistor Inspection...1074
Blower Motor Relay Inspection...1075
HVAC Control Unit Components...1076
HVAC Control Unit Removal and Installation...1076
Blower Speed Selector Inspection...1078
Air Intake Selector Inspection...1078
Air Intake Control Actuator Removal and Installation...1079
Air Intake Control Actuator Inspection...1079
Center Ventilation Louver Removal and Installation...1079
Side Ventilation Louver Removal and Installation...1080
Air Filter (If Equipped) Removal and Installation...1081
Air Filter Cleaning (If Equipped)...1081
Air Conditioning System...1082
Precautions...1082
A/C System Caution...1082
Precautions on Servicing A/C System...1082
General Description...1083
Refrigerant Type Identification...1083
Sub-Cool A/C System Description...1084
A/C Operation Description...1085
Schematic and Routing Diagram...1085
Major Components of A/C System...1085
A/C System Wiring Diagram...1087
Diagnostic Information and Procedures...1088
A/C System Symptom Diagnosis...1088
Abnormal Noise Symptom Diagnosis of A/C System...1090
A/C System Performance Inspection...1091
A/C System Inspection at ECM...1096
Repair Instructions...1098
Operation Procedure for Refrigerant Charge...1098
Condenser Assembly On-Vehicle Inspection...1103
Condenser Assembly Removal and Installation...1103
Desiccant Removal and Installation...1104
HVAC Unit Components...1105
HVAC Unit Removal and Installation...1106
Evaporator Inspection...1106
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation...1106
Evaporator Thermistor (Evaporator Temperature Sensor) Inspection...1107
Expansion Valve Removal and Installation...1107
Expansion Valve Inspection...1108
A/C Refrigerant Pressure Sensor and Its Circuit Inspection...1108
A/C Refrigerant Pressure Sensor Removal and Installation...1108
A/C Switch Inspection...1108
Compressor Relay Inspection...1109
Compressor Drive Belt Inspection and Adjustment...1109
Compressor Drive Belt Removal and Installation...1110
Compressor Assembly Removal and Installation...1110
Compressor Assembly Components...1111
Magnet Clutch Inspection...1111
Magnet Clutch Removal and Installation...1111
Thermal Switch Inspection...1113
Thermal Switch Removal and Installation...1113
Relief Valve Inspection...1113
Relief valve Removal and Installation...1113
Specifications...1114
Tightening Torque Specifications...1114
Special Tools and Equipment...1114
Recommended Service Material...1114
Special Tool...1114
Restraint...1115
Precautions...1117
Precautions...1117
Precautions on Restraint...1117
Seat Belts...1118
Precautions...1118
Precautions on Service and Diagnosis of Seat Belt...1118
General Description...1118
Seat Belt Construction...1118
Diagnostic Information and Procedures...1119
Repair and Inspection Required after Accident...1119
Repair Instructions...1120
Front Seat Belt Components...1120
Front Seat Belt Removal and Installation...1120
Front Seat Belt Inspection...1121
Seat Belt Reminder Cancelling Procedure...1122
Rear Seat Belt Components...1123
Rear Seat Belt Removal and Installation...1124
Rear Seat Belt Inspection...1124
Specifications...1124
Tightening Torque Specifications...1124
Air Bag System...1125
Precautions...1125
Precautions on Service and Diagnosis of Air Bag System...1125
Precautions on Handling and Storage of Air Bag System Components...1125
Precautions on Disposal of Air Bag and Seat Belt Pretensioner...1129
General Description...1129
Air Bag System Construction...1129
Air Bag System Input / Output Table...1130
Schematic and Routing Diagram...1131
Air Bag System Wiring Circuit Diagram...1131
Component Location...1133
Air Bag System Components, Wiring and Connectors Location...1133
Diagnostic Information and Procedures...1134
Air Bag Diagnostic System Check...1134
Air Bag Diagnostic System Check Flow...1134
DTC Table...1135
DTC Check...1136
DTC Clearance...1136
Scan Tool Data...1136
“AIR BAG” Warning Lamp Comes ON Steady...1137
“AIR BAG” Warning Lamp Does Not Come ON...1139
“AIR BAG” Warning Lamp Flashes...1140
DTC B1013: SDM fault...1141
DTC B1014: “AIR BAG” Warning Lamp Circuit Failure...1141
DTC B1016: Power Source Voltage High...1143
DTC B1017: Power Source Voltage Low...1144
DTC B1021: Front Air Bag Module Deployed...1146
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed...1147
DTC B1026: Pretensioner Activated...1147
DTC B1027: Reusable Number Exceeded...1148
DTC B1031: Driver Air Bag Initiator Circuit Resistance High...1148
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...1153
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground...1157
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...1161
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...1165
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low...1168
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...1171
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit...1174
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High...1177
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low...1179
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground...1181
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit...1183
DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High...1185
DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low...1188
DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground...1191
DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit...1194
DTC B1071: Forward-Sensor Performance Problem...1197
DTC B1072: Forward-Sensor Communication Error...1197
DTC B1073: Forward-Sensor Circuit Short to Ground...1197
DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open...1199
DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem...1201
DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error...1201
DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground...1201
DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open...1202
DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID...1204
DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High...1205
DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low...1207
DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground...1209
DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit...1211
Inspection of Intermittent and Poor Connections...1213
Repair and Inspection Required after Accident...1214
Repair Instructions...1217
Disabling Air Bag System...1217
Enabling Air Bag System...1217
SDM Removal and Installation...1218
SDM Inspection...1219
Driver Air Bag (Inflator) Module Removal and Installation...1219
Driver Air Bag (Inflator) Module Inspection...1220
Passenger Air Bag (Inflator) Module Removal and Installation...1221
Passenger Air Bag (Inflator) Module Inspection...1222
Side-Air Bag (Inflator) Module Removal and Installation...1223
Side-Air Bag (Inflator) Inspection...1224
Side Curtain-Air Bag (Inflator) Module Removal and Installation...1225
Side Curtain-Air Bag (Inflator) Module Inspection...1226
Forward-Sensor Removal and Installation...1226
Forward-Sensor Inspection...1227
Side-Sensor Removal and Installation...1227
Side-Sensor Inspection...1228
Passenger Air Bag (Inflator) Module Repair Harness Installation...1229
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal...1230
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal...1240
Specifications...1241
Tightening Torque Specifications...1241
Special Tools and Equipment...1241
Use of Special Tools...1241
Recommended Service Material...1242
Special Tool...1242
Body, Cab and Accessories...1245
Precautions...1250
Precautions...1250
Precautions on Body, Cab and Accessories...1250
Precautions for Body Service...1250
Fastener Caution for Body Service...1250
Wiring Systems...1251
Precautions...1251
Cautions in Body Electrical System Servicing...1251
Precautions for Wiring System...1251
General Description...1251
Applicable model...1251
Abbreviations...1252
Wire / Connector Color Symbols...1252
Symbols and Marks...1253
How to Read Connector Layout Diagram...1254
How to Read Connector Codes and Terminal Nos...1255
How to Read Ground Point...1258
How to Read Power Supply Diagram...1258
How to Read System Circuit Diagram...1259
Harness Routing and Connector Layout Diagram...1261
Connector Layout Diagram...1261
Engine Compartment...1261
Instrument Panel...1265
Door, Roof...1269
Floor...1271
Rear...1279
Ground Point...1280
Ground (earth) Point...1280
Power Supply Diagram...1281
Power Supply Diagram...1281
Fuses and the Protected Parts...1282
Fuses in Main Fuse Box...1282
Individual Circuit Fuse Box No. 1...1282
Individual Circuit Fuse Box No. 2 (In J/B)...1283
Junction Block (J/B) Connector / Fuse Layout...1286
Junction Block Inner Circuit (Overview)...1288
Junction Block Inner Circuit (Detail)...1289
System Circuit Diagram...1294
System Circuit Diagram...1294
A-1 Cranking System Circuit Diagram...1295
A-2 Charging System Circuit Diagram...1296
A-3 Ignition System Circuit Diagram...1297
A-4 Cooling System Circuit Diagram...1298
A-5 Engine and A/C Control System Circuit Diagram...1299
A-6 A/T Control System Circuit Diagram...1304
A-7 Immobilizer System Circuit Diagram...1306
A-8 Body Control System Circuit Diagram...1307
A-9 Automated Manual Transaxle Control System Circuit Diagram...1311
B-1 Windshield Wiper and Washer Circuit Diagram...1314
B-2 Rear Wiper and Washer Circuit Diagram...1315
B-3 Rear Defogger Circuit Diagram...1316
B-4 Power Window Circuit Diagram...1317
B-5 Power Door Lock Circuit Diagram...1318
B-6 Power Mirror Circuit Diagram...1320
B-7 Horn Circuit Diagram...1321
B-8 Seat Heater Circuit Diagram...1322
B-9 Smart Key System Circuit Diagram...1323
C-1 Combination Meter Circuit Diagram (Meter)...1324
C-2 Combination Meter Circuit Diagram (Indicator)...1325
C-3 Combination Meter Circuit Diagram (Warning Light)...1326
D-1 Headlight System Circuit Diagram...1328
D-2 Position, Tail and Licence Plate Light System Circuit Diagram...1330
D-3 Front Fog Light System Circuit Diagram...1331
D-4 Illumination Light System Circuit Diagram...1332
D-5 Interior Light System Circuit Diagram...1333
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram...1334
D-7 Brake Light System Circuit Diagram...1336
D-8 Back-Up Light System Circuit Diagram...1337
D-9 Headlight Beam Leveling System Circuit Diagram...1338
D-10 Rear Fog Light Circuit Diagram...1339
E-1 Heater System Circuit Diagram...1340
F-1 Air-Bag System Circuit Diagram...1342
F-2 Anti-Lock Brake System Circuit Diagram...1344
F-3 Power Steering System Circuit Diagram...1346
G-1 Audio System Circuit Diagram...1348
G-2 Multi Information Display / Accessory Socket System Circuit Diagram...1349
G-4 Navigation System Circuit Diagram...1350
List of Connectors...1351
List of Connectors...1351
C Connector...1351
E Connector...1352
G Connector...1354
J Connector...1355
K Connector...1356
L Connector...1356
O Connector...1358
R Connector...1358
Lighting Systems...1359
Component Location...1359
Lighting System Components Location...1359
Interior Light System Location...1360
Diagnostic Information and Procedures...1360
Headlight Symptom Diagnosis...1360
DRL System Symptom Diagnosis (If Equipped)...1360
Headlight Leveling Symptom Diagnosis (If Equipped)...1361
Turn Signal and Hazard Warning Light Symptom Diagnosis...1361
Clearance, Tail and License Plate Light Symptom Diagnosis...1362
Back-Up Light Symptom Diagnosis...1362
Stop (Brake) Lamp Symptom Diagnosis...1362
Front Fog Light (If Equipped) Symptom Diagnosis...1362
Rear Fog Light (If Equipped) Symptom Diagnosis...1363
Illumination Cancel System (If Equipped) Symptom Diagnosis...1363
Interior Light Symptom Diagnosis...1363
DRL Operation Inspection (If Equipped)...1363
Inspection of DRL Controller and Its Circuits (If Equipped)...1363
Repair Instructions...1365
Headlight Housing Removal and Installation...1365
Headlight Bulb Replacement...1365
Headlight Aiming Adjustment with Screen...1365
Headlight Switch (in Lighting Switch) Removal and Installation...1367
Headlight Switch (in Lighting Switch) Inspection...1367
Hazard Warning Switch Removal and Installation...1367
Hazard Warning Switch Inspection...1368
Stop (Brake) Lamp Switch Inspection...1368
Turn Signal Light Switch (in Lighting Switch) Removal and Installation...1368
Turn Signal Light Switch (in Lighting Switch) Inspection...1368
Turn Signal and Hazard Warning Relay Removal and Installation...1368
Turn Signal and Hazard Warning Relay Inspection...1369
License Lamp Assembly Removal and Installation...1369
Front Fog Light Assembly Removal and Installation (If Equipped)...1370
Front Fog Light Bulb Replacement (If Equipped)...1370
Front Fog Light Switch Inspection (If Equipped)...1370
Front Fog Light Relay Inspection (If Equipped)...1370
Front Fog Light Aiming Adjustment with Screen (If Equipped)...1371
Headlight Levering Switch (If Equipped) Inspection...1371
Headlight Leveling Actuator Inspection (If Equipped)...1372
Rear Fog Light Switch Inspection...1372
Illumination Cancel Switch (If Equipped) Inspection...1372
Instrumentation / Driver Info. / Horn...1373
General Description...1373
CAN Communication Data of Combination Meter...1373
Schematic and Routing Diagram...1374
Combination Meter Circuit Diagram...1374
Component Location...1375
Audio System Component Location...1375
Diagnostic Information and Procedures...1376
Speedometer and VSS Symptom Diagnosis...1376
Tacho meter Symptom Diagnosis...1376
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis...1376
Fuel Meter Symptom Diagnosis...1376
Low Fuel Warning Light Symptom Diagnosis...1377
Oil Pressure Warning Light Symptom Diagnosis...1377
Brake and Parking Brake Warning Light Symptom Diagnosis...1377
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)...1378
A/T Shift Position Indicator (A/T Model Only) Symptom Diagnosis...1378
Automated Manual Transaxle Shift Position Indicator (Automated Manual Transaxle Model Only) Symptom Diagnosis...1379
Charge Warning Light Symptom Diagnosis...1379
Main Beam (High Beam) Indicator Symptom Diagnosis...1379
Warning Buzzer Circuit Symptom Diagnosis...1380
Cigarette Lighter Symptom Diagnosis (If Equipped)...1380
Horn Symptom Diagnosis...1380
Information Display Symptom Diagnosis (If Equipped)...1381
Clock Symptom Diagnosis (If Equipped)...1381
Audio System Symptom Diagnosis (If Equipped)...1382
Remote Audio Control Switch Symptom Diagnosis (If Equipped)...1383
Navigation Symptom Diagnosis (If Equipped)...1383
Repair Instructions...1383
Ignition Switch Removal and Installation...1383
Ignition Switch Inspection...1384
Combination Meter Removal and Installation...1384
Fuel Level Sensor Removal and Installation...1385
Fuel Level Sensor Inspection...1385
Oil Pressure Switch Removal and Installation...1385
Oil Pressure Switch Inspection...1385
VSS Removal and Installation...1385
VSS Inspection...1385
Engine Coolant Temperature (ECT) Sensor Inspection...1385
Brake Fluid Level Switch Inspection...1386
Parking Brake Switch Inspection...1386
Door Switch (Front / Rear Door) Inspection...1386
Rear End Door Switch Inspection...1386
Outside Air Temperature Sensor Removal and Installation (If Equipped)...1386
Outside Air Temperature Sensor Inspection (If Equipped)...1387
Instrument Panel Removal and Installation...1387
Information Display (Clock) Removal and Installation...1388
Audio Unit Removal and Installation...1388
Front Speaker Removal and Installation...1389
Rear Speaker Removal and Installation (5 Door Model)...1389
Rear Speaker Removal and Installation (3 Door Model)...1389
GPS Antenna Removal and Installation (If Equipped)...1390
Horn Removal and Installation...1390
Horn Inspection...1390
Horn Relay Inspection...1390
Antenna Base Removal and Installation...1391
Remote Audio Control Switch Inspection...1391
Specifications...1391
Tightening Torque Specifications...1391
Wipers / Washers...1392
Diagnostic Information and Procedures...1392
Front Wiper and Washer Symptom Diagnosis...1392
Rear Wiper and Washer Symptom Diagnosis (If Equipped)...1392
Repair Instructions...1393
Wipers and Washers Components...1393
Washer Tank and Washer Pump Removal and Installation...1394
Washer Pump Inspection...1394
Windshield Wiper Removal and Installation...1394
Windshield Wiper Motor Inspection...1395
Rear Wiper Removal and Installation (If Equipped)...1396
Rear Wiper Motor Inspection (If Equipped)...1397
Windshield Wiper and Washer Switch Removal and Installation...1398
Windshield Wiper and Washer Switch Inspection...1398
Rear Wiper and Washer Switch Removal and Installation...1399
Rear Wiper and Washer Switch Inspection...1400
Rear Wiper Relay Removal and Installation...1400
Rear Wiper Relay Inspection...1400
Specifications...1400
Tightening Torque Specifications...1400
Glass / Windows / Mirrors...1401
General Description...1401
Rear End Door Window Defogger System Description...1401
Windshield Construction...1401
Rear Quarter Window Construction...1402
Diagnostic Information and Procedures...1403
Rear End door Window Defogger Symptom Diagnosis...1403
Power Window Control System Symptom Diagnosis...1403
Power Door Mirror Control System Symptom Diagnosis (If Equipped)...1403
Door Mirror Heater Symptom Diagnosis (If Equipped)...1404
Repair Instructions...1404
Windshield Removal and Installation...1404
Rear Quarter Window Removal and Installation...1407
Front Door Window Components...1411
Front Door Glass Removal and Installation...1412
Front Door Window Regulator Removal and Installation...1413
Front Door Window Regulator Inspection...1413
Rear Door Window Components...1414
Rear Door Glass Removal and Installation...1414
Rear Door Window Regulator Removal and Installation...1415
Rear Door Window Regulator Inspection...1416
Rear End Door Window Components...1416
Rear End Door Glass Removal and Installation...1416
Rear End Door Window Defogger Switch Inspection...1417
Rear End Door Window Defogger Relay Inspection...1417
Rear End Door Window Defogger Wire Inspection...1418
Rear End Door Window Defogger Wire Repair...1418
Power Window Main Switch Inspection...1418
Power Window Sub Switch Inspection...1420
Door Mirror Components...1420
Door Mirror Removal and Installation...1421
Power Door Mirror Switch Inspection (If Equipped)...1421
Power Door Mirror Actuator Inspection (If Equipped)...1421
Door Mirror Heater Inspection (If Equipped)...1421
Special Tools and Equipment...1422
Recommended Service Material...1422
Security and Locks...1423
General Description...1423
Key Coding Construction...1423
Rear End Door Opener System Description...1423
Component Location...1424
Power Door Lock and Keyless Entry System Component Location...1424
Diagnostic Information and Procedures...1425
Power Door Lock System Symptom Diagnosis...1425
Power Door Lock System Operation Inspection...1425
Keyless Entry System Symptom Diagnosis (If Equipped)...1426
Keyless Entry System Operation Inspection...1427
Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...1427
Rear End Door Opener System Symptom Diagnosis...1427
Rear End Door Opener System Operation Inspection...1427
Repair Instructions...1428
Front Door Lock Assembly Components...1428
Front Door Lock Assembly Removal and Installation...1428
Front Door Lock Assembly Inspection...1430
Power Door Lock Switch Inspection...1430
Door Key Cylinder Switch Inspection...1430
Power Door Lock Actuator Inspection (If Equipped)...1431
Rear Door Lock Assembly Components...1432
Rear Door Lock Assembly Removal and Installation...1432
Rear Door Lock Assembly Inspection...1432
Rear End Door Lock Assembly Components...1433
Rear End Door Lock Assembly Removal and Installation...1433
Rear End Door Lock Assembly Inspection...1434
Rear End Door Opener Switch Inspection...1434
Replacement of Transmitter Battery...1434
Programming Transmitter Code...1435
Keyless Entry Receiver Removal and Installation...1435
Keyless Entry Receiver and Its Circuit Inspection...1436
Specifications...1437
Tightening Torque Specifications...1437
Special Tools and Equipment...1437
Recommended Service Material...1437
Seats...1438
Repair Instructions...1438
Front Seat Components...1438
Front Seat Removal and Installation...1438
Rear Seat Components...1439
Rear Seat Removal and Installation...1440
Specifications...1441
Tightening Torque Specifications...1441
Special Tools and Equipment...1441
Recommended Service Material...1441
Interior Trim...1442
Repair Instructions...1442
Floor Carpet Removal and Installation...1442
Head Lining Removal and Installation...1442
Console Box Components...1444
Roof Molding Components...1444
Splash Guard (If Equipped) Components...1445
Specifications...1445
Tightening Torque Specifications...1445
Hood / Fenders / Doors...1446
Repair Instructions...1446
Hood Removal and Installation...1446
Hood Inspection and Adjustment...1446
Front Fender Components...1447
Front Fender Removal and Installation...1447
Front Door Assembly Components...1448
Front Door Assembly Removal and Installation...1448
Rear Door Assembly Components...1449
Rear Door Assembly Removal and Installation...1450
Rear End Door Assembly Components...1450
Rear End Door Assembly Removal and Installation...1450
Specifications...1452
Tightening Torque Specifications...1452
Special Tools and Equipment...1452
Recommended Service Material...1452
Body Structure...1453
Repair Instructions...1453
Front Bumper and Rear Bumper Components...1453
Cowl Top Components...1454
Specifications...1455
Body Dimensions...1455
Panel Clearance...1464
Paint / Coatings...1465
General Description...1465
Anti-Corrosion Treatment Construction...1465
Plastic Parts Finishing...1465
Component Location...1466
Sealant Application Areas...1466
Under Coating Application Areas...1471
Anti-Corrosion Compound Application Area...1473
Exterior Trim...1475
Repair Instructions...1475
Roof Molding Components...1475
Splash Guard (If Equipped) Components...1476
Control systems...1477
Precautions...1479
Precautions...1479
Precautions for Control Systems...1479
Body Electrical Control System...1480
Precautions...1480
Precautions in Diagnosing Trouble...1480
General Description...1480
BCM General Description...1480
CAN Communication System Description...1480
Schematic and Routing Diagram...1482
Body Electrical Control System Wiring Circuit Diagram...1482
Connector Layout Diagram of BCM and Junction Block Assembly...1485
Component Location...1486
BCM and Related System Component Location...1486
Diagnostic Information and Procedures...1487
BCM Self-Diagnosis Function...1487
Body Electrical Control System Check...1488
Scan Tool Data...1490
DTC Table...1492
DTC Check...1492
DTC Clearance...1494
BCM Power Circuit and Ground Circuit Check...1494
DTC B1133 (DTC No. 1133): Battery Voltage Too High...1496
DTC B1141 / DTC B1142 / DTC B1143 (No. 1141 / No. 1142/ No. 1143) Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction...1497
DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction...1498
DTC B1157 (No. 1157) Air Bag Deployment Signal Input...1499
DTC B1170 (No. 1170): EEPROM access error...1500
DTC U1001 (No. 1001): High Speed CAN Communication (Transmission Error)...1501
DTC U1073 (No. 1073): Control Module Communication Bus Off...1503
DTC U1100 (No. 1100): Lost communication with ECM...1505
DTC U1101 (No. 1101): Lost communication with TCM...1506
DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...1508
Inspection of BCM and its Circuits...1509
Repair Instructions...1518
BCM (Included in Junction Block Assembly) Removal and Installation...1518
Outside Air Temperature Sensor Removal and Installation...1519
Outside Air Temperature Sensor Inspection...1519
Special Tools and Equipment...1519
Special Tool...1519
Immobilizer Control System...1520
Precautions...1520
Precautions in Diagnosing Troubles...1520
Precaution in Replacing ECM...1520
Precautions in Handling Immobilizer Control System...1520
General Description...1521
Immobilizer Control System Introduction...1521
Immobilizer Control System Components Location...1521
On-Board Diagnostic System Description (Self- diagnosis Function)...1522
Schematic and Routing Diagram...1523
Immobilizer Control System Wiring Circuit Diagram...1523
Diagnostic Information and Procedures...1524
Immobilizer Control System Check...1524
Diagnostic Trouble Code (DTC) Check...1524
Diagnostic Trouble Code (DTC) Clearance...1525
Diagnostic Trouble Code (DTC) Table...1525
Scan Tool Data...1526
Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop...1527
Immobilizer Indicator Lamp Remains ON after Engine Starts...1529
DTC P1614 Transponder Response Error...1530
DTC P1615 ID Code Does Not Registered (Vehicle equipped with keyless start system only)...1531
DTC P1616 Different Registration ID Codes (Vehicle equipped with keyless start system only)...1533
DTC P1618 CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)...1534
DTC P1621 Immobilizer Communication Line Error...1537
DTC P1622 EEPROM Error...1539
DTC P1623 Unregistered Transponder...1540
DTC P1625 Immobilizer Antenna Error...1540
Inspection of Immobilizer Control Module (ICM) and Its Circuit...1541
Repair Instructions...1543
Immobilizer Control Module (ICM) Removal and Installation...1543
Registration of the Ignition Key...1543
Procedure after ECM Replacement...1543
Special Tools and Equipment...1544
Special Tool...1544
Keyless Start System...1545
General Description...1545
Keyless Start System Description...1545
Parts and Functions...1546
Keyless Engine Start Function...1546
Door Lock Function of Keyless Start System...1548
Operation Area of Remote Controller...1549
Alarm Function...1550
CAN Communication of Keyless Start System...1550
Schematic and Routing Diagram...1551
Keyless Start System Electric Wiring Circuit Diagram...1551
Diagnostic Information and Procedures...1552
Precautions in Diagnosing Troubles...1552
Self-Diagnosis Function...1552
Keyless Start System Diagnosis Introduction...1552
Keyless Start System Check...1552
Customer questionnaire (example)...1553
Key Indicator Lamp Check...1554
DTC Check...1554
DTC Table...1556
DTC Clearance...1556
Keyless Start System Symptom Diagnosis...1557
Keyless Start System Operation Inspection...1558
Door Lock Operation (Keyless Start System)...1558
Inspection of Keyless Start Control Module and Its Circuits...1559
No DTC Detection After Performing DTC Check...1563
Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.)...1565
Keyless Start Control Module Power and Ground Circuit Check...1567
DTC No. 11: Communication Error with Steering Lock Unit...1568
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...1569
DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)...1569
DTC No. 31: Lost Communication with BCM...1570
DTC No. 33: Control Module Communication Bus Off...1573
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure...1575
Repair Instructions...1577
Antennas and Request Switches Removal and Installation...1577
Front Door (Driver and Passenger Side) Rear End Door Request Switch Inspection...1577
Steering Lock Unit Removal and Installation...1578
Steering Lock Unit Inspection...1578
Front Door Lock Switch Inspection...1578
Keyless start control module Removal and Installation...1578
Remote Controller Inspection...1579
Replacement of Remote Controller Battery...1579
Registration Procedure for Remote Controller ID Code...1580
COPYRIGHT...1582
TABLE OF CONTENTS...1
Precautions...2
Precautions...3
Precautions...3
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System...3
General Precautions...6
Warning for Wheel (with tire) Removal...9
Warning for Handling Emergency Flat Tire Repair Kit...9
Precautions for Catalytic Converter...9
Precautions for Installing Mobile Communication Equipment...9
Precaution for CAN Communication System...9
Precautions for Electrical Circuit Service...10
Air Bag Warning...12
Air Bag System Service Warning...12
Fastener Caution...12
Suspension Caution...12
Wheels and Tires Caution...12
Precaution for Vehicle Equipped with ESP‚ System...13
Brake Caution...13
Repair Instructions...13
Electrical Circuit Inspection Procedure...13
Intermittent and Poor Connection Inspection...15
General Information...18
General Information...19
General Description...19
Abbreviations...19
Symbols...20
Wire Color Symbols...20
Fasteners Information...21
Vehicle Lifting Points...23
Engine Supporting Points...25
Vehicle Identification Number...25
Engine Identification Number...25
Transmission Identification Number...25
Component Location...26
Warning, Caution and Information Labels Location...26
Maintenance and Lubrication...28
Precautions...28
Precautions for Maintenance and Lubrication...28
Scheduled Maintenance...28
Maintenance Schedule under Normal Driving Conditions...28
Maintenance Recommended under Severe Driving Conditions...29
Repair Instructions...30
Accessory Drive Belt Inspection...30
Accessory Drive Belt Replacement...31
Valve Lash (Clearance) Inspection...31
Engine Oil and Filter Change...31
Engine Coolant Change...32
Exhaust System Inspection...33
Spark Plug Replacement...33
Air Cleaner Filter Inspection...33
Air Cleaner Filter Replacement...33
Fuel Lines and Connections Inspection...33
Fuel Filter Replacement...34
Fuel Tank Inspection...34
PCV Valve Inspection...34
Fuel Evaporative Emission Control System Inspection...34
Brake Discs and Pads Inspection...34
Brake Hoses and Pipes Inspection...34
Brake Fluid Inspection...35
Brake Fluid Replacement...35
Brake Lever and Cable Inspection...35
Clutch Fluid Inspection...35
Tires Inspection...36
Wheel Discs Inspection...36
Wheel Bearing Inspection...36
Suspension System Inspection...36
Steering System Inspection...37
Drive Shaft (Axle) Boots Inspection...37
Manual Transaxle Oil Inspection...37
Manual Transaxle Oil Replacement...37
Automatic Transaxle Fluid Level Inspection...38
Automatic Transaxle Fluid Replacement...38
Automatic Transaxle Fluid Cooler Hose Inspection...38
All Latches, Hinges and Locks Inspection...38
HVAC Air Filter (If Equipped) Inspection...39
HVAC Air Filter (If Equipped) Replacement...39
Final Inspection for Maintenance Service...39
Specifications...40
Tightening Torque Specifications...40
Special Tools and Equipment...40
Recommended Fluids and Lubricants...40
Special Tool...41
Engine...42
Precautions...47
Precautions...47
Precautions for Engine...47
Engine General Information and Diagnosis...48
Precautions...48
Precautions on Engine Service...48
Precaution on On-Board Diagnostic (OBD) System...48
Precautions in Diagnosing Trouble...48
Precautions of ECM Circuit Inspection...49
Precautions of Electric Throttle Body System Calibration...49
General Description...49
Statement on Cleanliness and Care...49
Engine Diagnosis General Description...50
On-Board Diagnostic System Description...50
Data Link Connector (DLC)...53
Engine and Emission Control System Description...53
CAN Communication System Description...54
Air Intake System Description...56
Description of Electric Throttle Body System...56
Description of Electric Throttle Body System Calibration...57
Fuel Cut Control Description...57
Generator Control System Description...58
Electronic Control System Description...59
Engine and Emission Control Input / Output Table...65
Schematic and Routing Diagram...66
Engine and Emission Control System Diagram...66
Component Location...68
Electronic Control System Components Location...68
Diagnostic Information and Procedures...69
Engine and Emission Control System Check...69
Malfunction Indicator Lamp (MIL) Check...72
DTC Check...73
DTC Clearance...74
DTC Table...74
Fail-Safe Table...78
Scan Tool Data...80
Visual Inspection...84
Engine Basic Inspection...85
Engine Symptom Diagnosis...88
MIL Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)...94
Malfunction Indicator Lamp Remains ON after Engine Starts...95
DTC P0010: “A” Camshaft Position Actuator Circuit...96
DTC P0011 / P0012: “A” Camshaft Position - Timing Over-Advanced or System Performance / - Retarded...99
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)...101
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)...103
DTC P0101: Mass or Volume Air Flow Circuit Range / Performance...105
DTC P0102: Mass or Volume Air Flow Circuit Low Input...108
DTC P0103: Mass or Volume Air Flow Circuit High Input...110
DTC P0106: Manifold Absolute Pressure / Barometric Pressure Circuit Range / Performance...111
DTC P0107: Manifold Absolute Pressure / Barometric Pressure Circuit Low Input...113
DTC P0108: Manifold Absolute Pressure / Barometric Pressure Circuit High Input...114
DTC P0111: Intake Air Temperature Sensor 1 Circuit Range / Performance...116
DTC P0112: Intake Air Temperature Sensor 1 Circuit Low...119
DTC P0113: Intake Air Temperature 1 Sensor Circuit High...121
DTC P0116: Engine Coolant Temperature Circuit Range / Performance...123
DTC P0117: Engine Coolant Temperature Circuit Low...126
DTC P0118: Engine Coolant Temperature Circuit High...128
DTC P0122: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit Low...130
DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit High...132
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1)...135
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)...138
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1)...139
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)...141
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)...144
DTC P0171 / P0172: Fuel System Too Lean / Rich...145
DTC P0222: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit Low...147
DTC P0223: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit High...149
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylinder Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected...152
DTC P0327 / P0328: Knock Sensor 1 Circuit Low / High...154
DTC P0335: Crankshaft Position (CKP) Sensor “A” Circuit...156
DTC P0340: Camshaft Position (CMP) Sensor “A” Circuit...158
DTC P0350: Ignition Coil Primary / Secondary Circuit...161
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected...163
DTC P0403: Exhaust Gas Recirculation Control Circuit...165
DTC P0420: Catalyst System Efficiency below Threshold...167
DTC P0443: Evaporative Emission System Purge Control Valve Circuit...169
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit...171
DTC P0500: Vehicle Speed Sensor “A” Malfunction...175
DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low...177
DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit High...179
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance...181
DTC P0616: Starter Relay Circuit Low...182
DTC P0617: Starter Relay Circuit High...183
DTC P0620: Generator Control Circuit...184
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High...186
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High...188
DTC P1510: ECM Back-Up Power Supply Malfunction...190
DTC P1603: TCM Trouble Code Detected...191
DTC P1674: CAN Communication (Bus Off Error)...192
DTC P1676: CAN Communication (Reception Error for TCM)...195
DTC P1678: CAN Communication (Reception Error for BCM)...196
DTC P1685: CAN Communication (Reception Error for ABS/ESP‚ Control Module)...197
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance...199
DTC P2102: Throttle Actuator Control Motor Circuit Low...201
DTC P2103: Throttle Actuator Control Motor Circuit High...202
DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed...203
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance...204
DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input...206
DTC P2123: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit High Input...208
DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input...211
DTC P2128: Throttle / Pedal Position Sensor / Switch “E” (Sub) Circuit High Input...213
DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage Correlation...215
DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage Correlation...218
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction...220
Inspection of ECM and Its Circuits...222
ECM Power and Ground Circuit Check...241
Fuel Injector Circuit Check...245
Fuel Pump and Its Circuit Check...247
Fuel Pressure Check...250
A/C System Circuits Check...252
Electric Load Signal Circuit Check...256
Radiator Cooling Fan Low Speed Control System Check...258
Radiator Cooling Fan High Speed Control System Check...260
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...265
Repair Instructions...265
EVAP Canister Purge Inspection...265
EVAP Canister Purge Valve and Its Circuit Inspection...266
Vacuum Passage Inspection...267
Vacuum Hose and Purge Valve Chamber Inspection...267
EVAP Canister Purge Valve Inspection...267
EVAP Canister Inspection...268
EGR Valve Removal and Installation...268
EGR Valve Inspection...268
PCV Hose Inspection...268
PCV Valve Inspection...269
Special Tools and Equipment...269
Special Tool...269
Engine Electrical Devices...270
Repair Instructions...270
ECM Removal and Installation...270
MAP Sensor Inspection...271
Electric Throttle Body Assembly On-Vehicle Inspection...271
Electric Throttle Body System Calibration...274
APP Sensor Assembly On-Vehicle Inspection...274
APP Sensor Assembly Removal and Installation...274
APP Sensor Assembly Inspection...275
ECT Sensor Removal and Installation...275
ECT Sensor Inspection...276
HO2S-1 and HO2S-2 Heater On-Vehicle Inspection...276
HO2S-1 and HO2S-2 Removal and Installation...276
CMP Sensor Removal and Installation...277
Camshaft Position (CMP) Sensor Inspection...277
CKP Sensor Removal and Installation...278
CKP Sensor Inspection...278
Knock Sensor Removal and Installation...279
Main Relay, Fuel Pump Relay and Starting Motor Control Relay Inspection...279
MAF and IAT Sensor On-Vehicle Inspection...280
MAF and IAT Sensor Removal and Installation...280
MAF and IAT Sensor Inspection...281
Electric Load Current Sensor On-Vehicle 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...284
Diagnostic Information and Procedures...286
Compression Check...286
Engine Vacuum Check...287
Valve Lash (Clearance) Inspection...288
Repair Instructions...291
Air Cleaner Components...291
Air Cleaner Element Removal and Installation...291
Air Cleaner Element Inspection and Cleaning...292
Cylinder Head Cover Removal and Installation...292
Throttle Body and Intake Manifold Components...294
Throttle Body On-Vehicle Inspection...295
Electric Throttle Body Assembly Removal and Installation...295
Throttle Body Cleaning...296
Intake Manifold Removal and Installation...296
Engine Mountings Components...298
Engine Assembly Removal and Installation...299
Timing Chain Cover Components...302
Timing Chain Cover Removal and Installation...303
Timing Chain Cover Inspection...305
Oil Control Valve Removal and Installation...305
Oil Control Valve Inspection...306
Timing Chain and Chain Tensioner Components...306
Timing Chain and Chain Tensioner Removal and Installation...307
Timing Chain and Chain Tensioner Inspection...309
Camshaft, Tappet and Shim Components...310
Camshaft, Tappet and Shim Removal and Installation...311
Camshaft, Tappet and Shim Inspection...313
Valves and Cylinder Head Components...316
Valves and Cylinder Head Removal and Installation...317
Valves and Cylinder Head Disassembly and Assembly...319
Valves and Valve Guides Inspection...322
Cylinder Head Inspection...324
Valve Spring Inspection...325
Pistons, Piston Rings, Connecting Rods and Cylinders Components...326
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation...327
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly...328
Cylinders, Pistons and Piston Rings Inspection...329
Piston Pins and Connecting Rods Inspection...331
Crank Pin and Connecting Rod Bearings Inspection...332
Main Bearings, Crankshaft and Cylinder Block Components...335
Main Bearings, Crankshaft and Cylinder Block Removal and Installation...336
Crankshaft Inspection...339
Main Bearings Inspection...341
Sensor Plate Inspection...345
Rear Oil Seal Inspection...345
Flywheel Inspection...345
Cylinder Block Inspection...345
Specifications...346
Tightening Torque Specifications...346
Special Tools and Equipment...348
Recommended Service Material...348
Special Tool...348
Engine Lubrication System...350
General Description...350
Engine Lubrication Description...350
Diagnostic Information and Procedures...351
Oil Pressure Check...351
Repair Instructions...352
Heat Exchanger Components...352
Heat Exchanger On-Vehicle Inspection...353
Heat Exchanger Removal and Installation...353
Oil Pan and Oil Pump Strainer Components...354
Oil Pan and Oil Pump Strainer Removal and Installation...354
Oil Pan and Oil Pump Strainer Cleaning...356
Oil Pump Components...357
Oil Pump Removal and Installation...357
Oil Pump Disassembly and Reassembly...357
Oil Pump Inspection...358
Specifications...360
Tightening Torque Specifications...360
Special Tools and Equipment...360
Recommended Service Material...360
Special Tool...360
Engine Cooling System...361
General Description...361
Cooling System Description...361
Coolant Description...361
Schematic and Routing Diagram...362
Coolant Circulation...362
Diagnostic Information and Procedures...364
Engine Cooling Symptom Diagnosis...364
Repair Instructions...365
Cooling System Components...365
Coolant Level Check...366
Engine Cooling System Inspection and Cleaning...366
Cooling System Draining...366
Cooling System Flush and Refill...367
Cooling Water Pipes or Hoses Removal and Installation...367
Thermostat Removal and Installation...368
Thermostat Inspection...368
Radiator Cooling Fan Motor On-Vehicle Inspection...369
Radiator Cooling Fan Relay Inspection...369
Radiator Cooling Fan Removal and Installation...370
Radiator On-Vehicle Inspection and Cleaning...370
Radiator Removal and Installation...370
Water Pump Removal and Installation...371
Water Pump Inspection...371
Specifications...372
Tightening Torque Specifications...372
Special Tools and Equipment...372
Recommended Service Material...372
Fuel System...373
Precautions...373
Precautions on Fuel System Service...373
General Description...373
Fuel System Description...373
Fuel Delivery System Description...373
Fuel Pump Description...374
Schematic and Routing Diagram...374
Fuel Delivery System Diagram...374
Diagnostic Information and Procedures...374
Fuel Pressure Inspection...374
Fuel Cut Operation Inspection...375
Repair Instructions...376
Fuel System Components...376
Fuel Hose Disconnecting and Reconnecting...377
Fuel Pressure Relief Procedure...379
Fuel Leakage Check Procedure...379
Fuel Lines On-Vehicle Inspection...379
Fuel Pipe Removal and Installation...379
Fuel Injector On-Vehicle Inspection...380
Fuel Injector Removal and Installation...380
Fuel Injector Inspection...381
Fuel Filler Cap Inspection...382
Fuel Tank Inlet Valve Removal and Installation...383
Fuel Tank Inlet Valve Inspection...384
Fuel Tank Removal and Installation...384
Fuel Tank Inspection...385
Fuel Tank Purging Procedure...386
Fuel Pump On-Vehicle Inspection...386
Fuel Pump Assembly Removal and Installation...386
Main Fuel Level Sensor Removal and Installation...387
Fuel Pump Inspection...388
Specifications...388
Tightening Torque Specifications...388
Special Tools and Equipment...389
Special Tool...389
Ignition System...390
General Description...390
Ignition System Construction...390
Schematic and Routing Diagram...391
Ignition System Wiring Circuit Diagram...391
Component Location...392
Ignition System Components Location...392
Diagnostic Information and Procedures...393
Ignition System Symptom Diagnosis...393
Reference Waveform of Ignition System...393
Ignition System Check...393
Ignition Spark Test...395
Repair Instructions...395
High-Tension Cord Removal and Installation...395
High-Tension Cord Inspection...396
Spark Plug Removal and Installation...396
Spark Plug Inspection...396
Ignition Coil Assembly (Including ignitor) Removal and Installation...397
Ignition Coil Assembly (Including ignitor) Inspection...397
Ignition Timing Inspection...397
Specifications...398
Tightening Torque Specifications...398
Special Tools and Equipment...398
Special Tool...398
Starting System...399
Schematic and Routing Diagram...399
Cranking System Circuit Diagram...399
Diagnostic Information and Procedures...399
Cranking System Symptom Diagnosis...399
Cranking System Test...401
Repair Instructions...402
Starting Motor Dismounting and Remounting...402
Starting Motor Components...403
Starting Motor Inspection...404
Specifications...407
Cranking System Specifications...407
Tightening Torque Specifications...407
Special Tools and Equipment...407
Recommended Service Material...407
Charging System...408
General Description...408
Battery Description...408
Generator Description...409
Diagnostic Information and Procedures...411
Battery Inspection...411
Generator Symptom Diagnosis...411
Generator Test (Undercharged Battery Check)...412
Generator Test (Overcharged Battery Check)...413
Repair Instructions...413
Jump Starting in Case of Emergency...413
Battery Dismounting and Remounting...414
Water Pump / Generator Drive Belt Tension Inspection and Adjustment...414
Water Pump / Generator Drive Belt Removal and Installation...415
Generator Unit Components...416
Generator Dismounting and Remounting...416
Generator Components...417
Generator Inspection...418
Specifications...420
Charging System Specifications...420
Tightening Torque Specifications...420
Exhaust System...421
General Description...421
Exhaust System Description...421
Diagnostic Information and Procedures...421
Exhaust System Check...421
Repair Instructions...422
Exhaust System Components...422
Exhaust Manifold Removal and Installation...423
Exhaust Pipe and Muffler Removal and Installation...424
Specifications...425
Tightening Torque Specifications...425
Suspension...426
Precautions...428
Precautions...428
Precautions on Suspension...428
Suspension General Diagnosis...429
Diagnostic Information and Procedures...429
Suspension, Wheels and Tires Symptom Diagnosis...429
Front Suspension...431
General Description...431
Front Suspension Construction...431
Front Wheel Alignment Construction...432
Repair Instructions...432
Front Wheel Alignment Inspection and Adjustment...432
Front Strut Assembly Components...434
Front Strut Assembly Removal and Installation...434
Front Strut Assembly Disassembly and Assembly...436
Front Strut Assembly Check...437
Front Wheel Hub and Steering Knuckle Components...438
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation...438
Front Wheel Hub, Disc, Nut and Bearing Check...442
Suspension Control Arm / Bushing Removal and Installation...442
Suspension Control Arm / Bushing Disassembly and Assembly...443
Suspension Control Arm / Steering Knuckle Check...444
Suspension Control Arm Bushing Check...444
Suspension Control Arm Joint Check...444
Front Suspension Frame, Stabilizer Bar and/or Bushings Components...445
Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation...445
Front Suspension Frame Check...449
Front Stabilizer Bar, Bushing and/or Joint Check...449
Front Suspension Fasteners Check...449
Specifications...450
Tightening Torque Specifications...450
Special Tools and Equipment...451
Special Tool...451
Rear Suspension...452
General Description...452
Rear Suspension Construction...452
Repair Instructions...453
Rear Wheel Alignment Inspection...453
Rear Shock Absorber Removal and Installation...453
Rear Shock Absorber Inspection...454
Rear Shock Absorber Bush Removal and Installation...455
Rear Shock Absorber Bush Inspection...455
Rear Coil Spring Removal and Installation...455
Spring Upper Seat / Spring Lower Seat Inspection...456
Spring Upper Seat and Lower Seat Removal and Installation...457
Rear Axle Removal and Installation...457
Trailing Arm, Rear Axle and Coil Spring Inspection...460
Rear Axle Bush Inspection...460
Rear Wheel Hub Components...461
Rear Wheel Hub Removal and Installation...461
Rear Wheel Disc, bolt and Bearing Inspection...462
Spindle Removal and Installation...463
Spindle Inspection...464
Rear Suspension Fasteners Inspection...464
Specifications...464
Tightening Torque Specifications...464
Special Tools and Equipment...464
Special Tool...464
Wheels and Tires...465
Precautions...465
Precaution for Emergency Flat Tire Repair Kit...465
General Description...465
Tires Description...465
Wheels Description...466
Irregular and/or Premature Wear Description...467
Wear Indicators Description...467
Radial Tire Waddle Description...468
Radial Tire Lead / Pull Description...469
Balancing Wheels Description...469
Repair Instructions...470
General Balance Procedures...470
Tire Rotation...470
Wheel Removal and Installation...471
Tire Mounting and Dismounting...472
Tire Repair...472
Tire Repair for Emergency Repaired-Tire with Sealant...472
Specifications...473
Wheels and Tires Specifications...473
Tightening Torque Specifications...473
Driveline / Axle...474
Precautions...475
Precautions...475
Precautions for Driveline / Axle...475
Drive Shaft / Axle...476
General Description...476
Front Drive Shaft Construction...476
Component Location...476
Front Drive Shaft Assembly Components Location...476
Diagnostic Information and Procedures...477
Front Drive Shaft Symptom Diagnosis...477
Repair Instructions...478
Front Drive Shaft Components...478
Front Drive Shaft Assembly On-Vehicle Inspection...479
Front Drive Shaft Assembly Removal and Installation...479
Front Drive Shaft Disassembly and Reassembly...481
Center Shaft and Center Bearing Support Disassembly and Reassembly...489
Specifications...490
Tightening Torque Specifications...490
Special Tools and Equipment...490
Recommended Service Material...490
Special Tool...490
Brakes...492
Precautions...495
Precautions...495
Precautions for Brakes...495
Brake Control System and Diagnosis...496
Precautions...496
Precautions on Brake...496
General Description...496
Brakes Construction...496
Brake Pedal Foot Protection System Construction...497
Front Brake Hose / Pipe Construction...498
Rear Brake Hose / Pipe Construction...499
Diagnostic Information and Procedures...499
Brakes Diagnosis Note...499
Brakes Symptom Diagnosis...500
Repair Instructions...502
Brake Pedal Components...502
Brake Pedal Free Height Inspection...502
Brake Pedal Play Inspection...502
Excessive Pedal Travel Inspection...503
Brake Fluid Level Inspection...503
Stop Light Switch Adjustment...503
Air Bleeding of Brake System...504
Front Brake Hose / Pipe Removal and Installation...505
Rear Brake Hose / Pipe Removal and Installation...505
Brake Hose and Pipe Inspection...506
Master Cylinder Components...506
Master Cylinder Assembly Removal and Installation...507
Master Cylinder Reservoir Removal and Installation...508
Master Cylinder Assembly Disassembly and Assembly...509
Master Cylinder Assembly Inspection...510
Brake Booster Components...510
Booster Operation Inspection...511
Brake Booster Removal and Installation...512
Brake Booster Inspection and Adjustment...513
Specifications...513
Tightening Torque Specifications...513
Special Tools and Equipment...513
Recommended Service Material...513
Front Brakes...514
Repair Instructions...514
Front Disc Brake Components...514
Front Disc Brake Pad On-Vehicle Inspection...515
Front Disc Brake Pad Removal and Installation...515
Front Disc Brake Pad Inspection...516
Front Disc Brake Caliper Removal and Installation...516
Front Disc Brake Caliper Disassembly and Assembly...517
Front Disc Brake Caliper Inspection...519
Front Brake Disc Removal and Installation...519
Front Brake Disc Inspection...520
Specifications...521
Tightening Torque Specifications...521
Special Tools and Equipment...521
Recommended Service Material...521
Special Tool...521
Rear Brakes...522
Repair Instructions...522
Rear Disc Brake Components...522
Rear Disc Brake Pad Removal and Installation...523
Rear Disc Brake Caliper Removal and Installation...524
Rear Disc Brake Pad Inspection...527
Rear Disc Brake Caliper Disassembly and Assembly...527
Rear Disc Brake Caliper Inspection...529
Rear Flexible Hose Removal and Installation...529
Rear Brake Disc Removal and Installation...530
Rear Brake Disc Inspection...530
Specifications...531
Tightening Torque Specifications...531
Special Tools and Equipment...532
Recommended Service Material...532
Special Tool...532
Parking Brake...533
General Description...533
Parking Brake Cable Construction...533
Repair Instructions...534
Parking Brake Inspection and Adjustment...534
Parking Brake Cable Removal and Installation...535
Parking Brake Lever Removal and Installation...535
Specifications...536
Tightening Torque Specifications...536
ABS...537
Precautions...537
Precautions in Diagnosing Troubles...537
Precautions in On-Vehicle Service...537
Precautions in Hydraulic Unit Operation Check...537
General Description...538
ABS Description...538
ABS Hydraulic Unit / Control Module Assembly Description...538
CAN Communication System Description...539
Schematic and Routing Diagram...540
ABS Schematic...540
ABS Wiring Circuit Diagram...541
Component Location...543
ABS Components Location...543
Front Wheel Speed Sensor Components Location...543
Rear Wheel Speed Sensor Components Location...544
Diagnostic Information and Procedures...544
ABS Check...544
ABS Warning Light Check...546
EBD Warning Light (Brake Warning Light) Check...546
DTC Check...547
DTC Table...547
DTC Clearance...548
Scan Tool Data...548
ABS Warning Light Does Not Come ON at Ignition Switch ON...549
ABS Warning Light Comes ON Steady...550
EBD Warning Light (Brake Warning Light) Comes ON Steady...551
Serial Data Link Circuit Check...552
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring...554
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...556
DTC C1057: Power Source Circuit...557
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit...558
DTC C1063: Solenoid Valve Power Supply Driver Circuit...559
DTC C1071: ABS Control Module...560
DTC U1073: Control Module Communication Bus Off...561
DTC U1100: Lost Communication with ECM (Reception Error)...563
Repair Instructions...564
ABS Hydraulic Unit Operation Check...564
ABS Hydraulic Unit / Control Module Assembly Components...565
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...565
ABS Hydraulic Unit / Control Module Assembly Removal and Installation...565
Front / Rear Wheel Speed Sensor On-Vehicle Inspection...567
Front Wheel Speed Sensor Removal and Installation...568
Front Wheel Speed Sensor Inspection...568
Rear Wheel Speed Sensor Removal and Installation...569
Rear Wheel Speed Sensor Inspection...570
Front Wheel Encoder On-Vehicle Inspection...570
Front wheel Encoder Removal and Installation...570
Rear Wheel Encoder On-Vehicle Inspection...570
Rear Wheel Encoder Removal and Installation...570
Specifications...571
Tightening Torque Specifications...571
Special Tools and Equipment...571
Special Tool...571
Electronic Stability Program...572
Precautions...572
Precautions in Diagnosing Troubles...572
Precautions in On-Vehicle Service...572
Precautions in Hydraulic Unit Operation Check...572
Precautions in Sensor Calibration...572
Precautions in Speedometer Test or Other Tests...573
General Description...573
Electronic Stability Program Description...573
Electronic Stability Program Construction...574
ESP‚ Hydraulic Unit / Control Module Assembly Description...576
Warning Lamp, Indicator Lamp Description...577
CAN Communication System Description...577
CAN Communication System For Electronic Stability Program Description...578
Schematic and Routing Diagram...579
Electronic Stability Program Schematic...579
Electronic Stability Program Wiring Circuit Diagram...580
Component Location...582
Electronic Stability Program Component Location...582
Diagnostic Information and Procedures...583
Electronic Stability Program System Check...583
ESP‚ Warning lamp Check...585
ABS Warning Lamp Check...585
EBD Warning Lamp (Brake Warning Lamp) Check...586
DTC Check...586
DTC Table...586
DTC Clearance...589
Fail-Safe Table...590
Scan Tool Data...591
Visual Inspection...592
ESP‚ Warning Lamp Does Not Come ON at Ignition Switch ON...592
ESP‚ Warning Lamp Comes ON Steady...593
ABS Warning Lamp Does Not Come ON at Ignition Switch ON...594
ABS Warning Lamp Comes ON Steady...595
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady...595
Serial Data Link Circuit Check...597
DTC C1016: Stop Lamp Switch Circuit Failure...599
DTC C1017 / C1023: Yaw Rate / G Sensor Assembly Failure...600
DTC C1018: Brake Fluid Level Switch Failure...601
DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure...602
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed Sensor Circuit or Encoder Failure...603
DTC C1024: Steering Angle Sensor Circuit Failure...605
DTC C1027: ESP‚ OFF Switch Circuit Failure...605
DTC C1028: Master Cylinder Pressure Sensor Circuit Failure...606
DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure...607
DTC C1037: Steering Angle Sensor Power Supply Failure...608
DTC C1038: Steering Angle Sensor Detect Rolling Counter Failure from ESP‚ Control Module...609
DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure...610
DTC C1040: Stability Control System Function Failure...610
DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 / C1055 / C1056: Solenoid Circuit Failure...611
DTC C1057: ESP‚ Control Module Power Supply Circuit Failure...612
DTC C1061: Pump Motor and/or Motor Driver Circuit Failure...613
DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure...614
DTC 1071: ESP‚ Control Module Internal Defect...615
DTC C1073: Lost Communication With Yaw Rate / G Sensor Assembly...616
DTC C1075 / 1076 / 1078: Sensor Calibration Incomplete...617
DTC C1090: Invalid Communication with ECM...618
DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control Communication with ECM...619
DTC U1073: Control Module Communication Bus Off...620
DTC U1100: Lost Communication with ECM (Reception Error)...621
DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error)...622
DTC U1140: Lost Communication with BCM (Reception Error)...623
Repair Instructions...625
ESP‚ Hydraulic Unit Operation Check...625
Sensor Calibration...625
ESP‚ Hydraulic Unit / Control Module Assembly On-Vehicle Inspection...626
ESP‚ Hydraulic Unit / Control Module Assembly Removal and Installation...627
Front / Rear Wheel Speed Sensor On-Vehicle Inspection...628
Front Wheel Speed Sensor Removal and Installation...629
Front Wheel Speed Sensor Inspection...630
Rear Wheel Speed Sensor Removal and Installation...630
Rear Wheel Speed Sensor Inspection...631
Front Wheel Encoder On-Vehicle Inspection...632
Front Wheel Encoder Removal and Installation...632
Rear Wheel Encoder On-Vehicle Inspection...632
Rear Wheel Encoder Removal and Installation...632
Master Cylinder Pressure Sensor On-Vehicle Inspection...632
Yaw Rate / G Sensor Assembly On-Vehicle Inspection...633
Yaw Rate / G Sensor Assembly Removal and Installation...634
Yaw Rate / G Sensor Inspection...635
Steering Angle Sensor On-Vehicle Inspection...635
Steering Angle Sensor Removal and Installation...636
Steering Angle Sensor Inspection...636
ESP‚ OFF Switch Removal and Installation...636
ESP‚ OFF Switch Inspection...636
Specifications...637
Tightening Torque Specifications...637
Special Tools and Equipment...637
Special Tool...637
Transmission / Transaxle...638
Precautions...641
Precautions...641
Precautions on Transmission / Transaxle...641
Automatic Transmission/Transaxle...642
Precautions...642
Precautions in Diagnosing Trouble...642
Precautions for Disassembly and Reassembly...642
General Description...644
A/T Description...644
Clutch / Brake / Planetary Gear Function of Automatic Transaxle...647
Table of Component Operation...648
Brake Interlock System Construction...649
A/T Diagnosis General Description...649
On-Board Diagnostic System Description...649
CAN Communication System Description...650
Schematic and Routing Diagram...651
Transmission Control Module (TCM) Wiring Diagram...651
Automatic Gear Shift Table...653
Component Location...654
Electronic Shift Control System Components Location...654
Diagnostic Information and Procedures...656
A/T System Check...656
Visual Inspection...659
Malfunction Indicator Lamp (MIL) Check...659
Transmission Warning Light Check...659
DTC Table...660
DTC Check...661
DTC Clearance...661
Fail-Safe Table...662
Scan Tool Data...664
A/T Basic Check...667
Road Test...668
Manual Road Test...670
Engine Brake Test...671
Stall Test...671
Time Lag Test...672
Line Pressure Test...673
“P” Range Test...674
A/T Symptom Diagnosis...675
No Gear Shift to 4th gear...682
No Lock-Up Occurs...683
Transmission Warning Light Circuit Check - Light Does Not Come “ON” at Ignition Switch ON...684
Transmission Warning Light Circuit Check - Light Remains “ON” at Ignition Switch ON...684
DTC P0602: Control Module Programming Error...685
DTC P0705: Transmission Range Sensor Circuit Malfunction (PRNDL input)...685
DTC P0707: Transmission Range Sensor Circuit Low...687
DTC P0712: Transmission Fluid Temperature Sensor “A” Circuit Low...689
DTC P0713: Transmission Fluid Temperature Sensor “A” Circuit High...690
DTC P0717: Input / Turbine Speed Sensor “A” Circuit Malfunction...692
DTC P0722: Output Speed Sensor Circuit No Signal...693
DTC P0787: Shift / Timing Solenoid Low...695
DTC P0788: Shift / Timing Solenoid High...697
DTC P0961: Pressure Control Solenoid “A” Control Circuit Range / Performance...699
DTC P0962: Pressure Control Solenoid “A” Control Circuit Low...701
DTC P0963: Pressure Control Solenoid “A” Control Circuit High...703
DTC P0973 / P0976: Shift Solenoid “A” Control Circuit Low / Shift Solenoid “B” Control Circuit Low...705
DTC P0974 / P0977: Shift Solenoid “A” / Shift Solenoid “B” Control Circuit High...707
DTC P1702: Internal Control Module Memory Check Sum Error...709
DTC P1703: Can Invalid Data - TCM...709
DTC P1723: Range Select Switch Malfunction...710
DTC P1774: CAN Communication Bus Off...712
DTC P1777: TCM Lost Communication with ECM (Reception Error)...714
DTC P1778: TCM Lost Communication with BCM (Reception Error)...715
DTC P1878: Torque Converter Clutch Shudder...716
DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit Range / Performance...717
DTC P2763: Torque Converter Clutch Pressure Control Solenoid Control Circuit High...719
DTC P2764: Torque Converter Clutch Circuit Pressure Control Solenoid Control Circuit Low...721
Inspection of TCM and Its Circuits...723
TCM Power and Ground Circuit Check...727
Brake Interlock System Inspection...728
Repair Instructions...729
Learning Control Initialization...729
A/T Fluid Level Check...730
A/T Fluid Change...731
Select Lever Components...731
Select Lever Assembly Removal and Installation...731
Select Lever Knob Installation...731
Select Lever Inspection...732
“3” Position Switch Inspection...732
Shift Lock Solenoid Inspection...732
Shift Lock Solenoid Replacement...732
Select Cable Components...733
Select Cable Removal and Installation...733
Select Cable Adjustment...734
Key Interlock Cable Removal and Installation...734
Transmission Range Sensor (Shift Switch) Inspection and Adjustment...736
Output Shaft Speed Sensor Removal and Installation...737
Output Shaft Speed Sensor Inspection...737
Input Shaft Speed Sensor Removal and Installation...737
Input Shaft Speed Sensor Inspection...738
Transmission Fluid Temperature Sensor Removal and Installation...738
Transmission Fluid Temperature Sensor Inspection...739
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation...739
Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection...740
Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation...742
Pressure Control Solenoid Valve Inspection...742
Transmission Control Module (TCM) Removal and Installation...743
A/T Relay Inspection...744
Differential Side Oil Seal Replacement...744
A/T Fluid Cooler Hoses Replacement...745
Automatic Transaxle Unit Components...746
Automatic Transaxle Unit Dismounting and Remounting...747
Automatic Transaxle Assembly Components...749
Automatic Transaxle Unit Disassembly...751
Oil Pump Assembly Components...762
Oil Pump Assembly Disassembly and Reassembly...763
Oil Pump Assembly Inspection...763
Direct Clutch Assembly Components...765
Direct Clutch Assembly Preliminary Check...765
Direct Clutch Assembly Disassembly and Reassembly...766
Direct Clutch Assembly Inspection...768
Forward and Reverse Clutch Assembly Components...769
Forward and Reverse Clutch Assembly Preliminary Check...770
Forward and Reverse Clutch Assembly Disassembly and Reassembly...770
Forward and Reverse Clutch Assembly Inspection...774
2nd Brake Piston Assembly Components...775
2nd Brake Piston Assembly Disassembly and Reassembly...775
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components...776
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly...777
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection...778
Countershaft Assembly Components...779
Countershaft Assembly Disassembly and Reassembly...779
Valve Body Assembly Components...780
Valve Body Assembly Disassembly and Reassembly...781
Differential Assembly Components...782
Differential Assembly Disassembly and Reassembly...783
Differential Assembly Inspection...784
Torque Converter Housing Disassembly and Reassembly...785
Transaxle Case Disassembly and Reassembly...787
Automatic Transaxle Unit Inspection and Adjustment...788
Automatic Transaxle Unit Assembly...791
Specifications...808
Tightening Torque Specifications...808
Special Tools and Equipment...809
Recommended Service Material...809
Special Tool...809
Manual Transmission/Transaxle...812
General Description...812
Manual Transaxle Construction and Servicing...812
Diagnostic Information and Procedures...814
Manual Transaxle Symptom Diagnosis...814
Repair Instructions...814
Manual Transaxle Oil Change...814
Differential Side Oil Seal Replacement...815
Gear Shift Control Lever and Cable Components...816
Gear Shift Control Lever and Cable Removal and Installation...817
Gear Select Control Cable Adjustment...817
Back Up Light Switch Removal and Installation...818
Back Up Light Switch Inspection...818
Manual Transaxle Unit Components...819
Manual Transaxle Unit Dismounting and Remounting...820
Gear Shift and Select Shaft Assembly Components...822
Gear Shift and Select Shaft Assembly Removal and Installation...822
Gear Shift and Select Shaft Disassembly and Assembly...823
Manual Transaxle Assembly Components...824
Fifth Gear Disassembly and Assembly...825
Manual Transaxle Assembly Disassembly and Reassembly...827
Transaxle Right Case Disassembly and Assembly...834
Transaxle Left Case Disassembly and Assembly...835
Input Shaft and Countershaft Components...836
Input Shaft Assembly Disassembly and Reassembly...837
Countershaft Assembly Disassembly and Reassembly...839
Synchronizer Parts Inspection...842
Gear Shift Shaft Components...842
5th and Reverse Gear Shift Shafts Disassembly and Assembly...843
Gear Shift Shaft and Fork Inspection...843
Differential Components...844
Differential Disassembly and Assembly...844
Specifications...846
Tightening Torque Specifications...846
Special Tools and Equipment...847
Recommended Service Material...847
Special Tool...847
Clutch...850
General Description...850
Clutch Construction...850
Diagnostic Information and Procedures...851
Clutch System Symptom Diagnosis...851
Repair Instructions...851
Clutch Pedal Inspection...851
Clutch Fluid Level Inspection...852
Air Bleeding of Clutch System...852
Clutch Pedal Position (CPP) Switch Removal and Installation...853
Clutch Pedal Position (CPP) Switch Inspection and Adjustment...854
Clutch Fluid Pipe and Hose Components...854
Clutch Fluid Pipe Removal and Installation...855
Clutch Fluid Pipe Inspection...855
Clutch Master Cylinder Removal and Installation...855
Clutch Operating Cylinder Removal and Installation...856
Clutch Operating Cylinder Inspection...856
Clutch Pedal and Clutch Pedal Bracket Components...856
Clutch Cover, Clutch Disc and Flywheel Components...857
Clutch Cover, Clutch Disc and Flywheel Removal and Installation...857
Clutch Cover, Clutch Disc and Flywheel Inspection...859
Clutch Release System Removal and Installation...860
Clutch Release System Inspection...862
Specifications...862
Tightening Torque Specifications...862
Special Tools and Equipment...863
Recommended Service Material...863
Special Tool...863
Steering...864
Precautions...866
Precautions...866
Precautions on Steering...866
Steering General Diagnosis...867
Precautions...867
Precautions for Steering Diagnosis...867
Diagnostic Information and Procedures...868
Steering Symptom Diagnosis...868
Steering Wheel and Column...869
Precautions...869
Service Precautions of Steering Wheel and Column...869
General Description...869
Steering Wheel and Column Construction...869
Diagnostic Information and Procedures...870
Checking Steering Column for Accident Damage...870
Repair Instructions...871
Steering Wheel and Column Construction...871
Steering Wheel Removal and Installation...872
Contact Coil Cable Assembly Removal and Installation...873
Centering Contact Coil Cable Assembly...874
Contact Coil Cable Assembly Inspection...874
Steering Angle Sensor Removal and Installation...874
Steering Angle Sensor Inspection...874
Steering Column Removal and Installation...875
Steering Column Inspection...876
Ignition Switch Cylinder Assembly Removal and Installation (Non- Keyless Start Model)...877
Steering Lock Assembly (Ignition Switch) Removal and Installation...877
Steering Lower Shaft Removal and Installation...878
Specifications...879
Tightening Torque Specifications...879
Special Tools and Equipment...879
Special Tool...879
Power Assisted Steering System...880
Precautions...880
Steering System Note...880
Precautions in Diagnosing Troubles...880
General Description...881
P/S System Description...881
EPS Diagnosis General Description...882
On-Board Diagnostic System Description...882
Schematic and Routing Diagram...883
EPS System Wiring Circuit Diagram...883
Diagnostic Information and Procedures...884
EPS System Check...884
“EPS” Warning Light Check...887
DTC Check...887
DTC Clearance...888
DTC Table...888
Scan Tool Data...890
Visual Inspection...891
P/S System Symptom Diagnosis...891
Serial Data Link Circuit Check...892
“EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts...894
“EPS” Warning Light Remains ON Steady after Engine Starts...895
DTC C1113: Steering Torque Sensor (Main and Sub) Circuit Correlation...896
DTC C1114: Steering Torque Sensor Reference Power Supply Circuit...898
DTC C1117: Steering Torque Sensor Failure Signal Circuit Low...900
DTC C1118: Steering Torque Sensor Failure Signal Circuit High...901
DTC C1119: Steering Torque Sensor Power Supply Circuit...903
DTC C1121 / C1123 / C1124: VSS Circuit Failure...905
DTC C1122: Engine Speed Signal...907
DTC C1141 / C1142 / C1143 / C1145: P/S Motor Circuit Failure...909
DTC C1153: P/S Control Module Power Supply Circuit Voltage Low...911
DTC C1155: P/S Control Module Failure...912
P/S Control Module Power Supply and Ground Circuit Check...913
Inspection of P/S Control Module and Its Circuits...914
Steering Wheel Play Check...918
Steering Force Check...918
Repair Instructions...919
Steering Gear Case Assembly Components...919
Tie-Rod End Boot On-Vehicle Inspection...920
Tie-Rod End Removal and Installation...920
Tie-Rod End Inspection...921
Steering Shaft Joint On-Vehicle Inspection...921
Steering Gear Case Assembly Removal and Installation...921
Steering Rack Boot Inspection...922
Tie-Rod / Rack Boot Removal and Installation...922
Steering Rack Plunger Removal and Installation...924
Steering Rack Plunger Inspection...924
P/S Control Module Removal and Installation...925
Torque Sensor and Its Circuit Inspection...925
P/S Motor and Its Circuit Inspection...926
Specifications...927
Tightening Torque Specifications...927
Special Tools and Equipment...928
Recommended Service Material...928
Special Tool...928
HVAC...930
Precautions...933
Precautions...933
Precautions on HVAC...933
Heater and Ventilation...934
General Description...934
Heater and Ventilation Construction...934
Schematic and Routing Diagram...935
Heater and Ventilation Wiring Circuit Diagram...935
Diagnostic Information and Procedures...936
Heater and Ventilation Symptom Diagnosis...936
Repair Instructions...937
HVAC Unit Components...937
HVAC Unit Removal and Installation...937
Blower Motor Removal and Installation...937
Blower Motor Inspection...937
Blower Motor Resistor Removal and Installation...938
Blower Motor Resistor Inspection...938
Blower Motor Relay Inspection...939
HVAC Control Unit Components...939
HVAC Control Unit Removal and Installation...940
Blower Speed Selector Inspection...942
Air Intake Selector Inspection...942
Air Intake Control Actuator Removal and Installation...942
Air Intake Control Actuator Inspection...943
Center Ventilation Louver Removal and Installation...943
Side Ventilation Louver Removal and Installation...944
HVAC Air Filter Removal and Installation (If Equipped)...945
HVAC Air Filter Inspection (If Equipped)...945
Air Conditioning System...946
Manual Type...946
Precautions...946
A/C System Caution...946
Precautions on Servicing A/C System...946
General Description...948
Refrigerant Type Identification...948
Sub-Cool A/C System Description...949
A/C Operation Description...949
Schematic and Routing Diagram...950
Major Components of A/C System...950
A/C System Wiring Diagram...951
Diagnostic Information and Procedures...952
A/C System Symptom Diagnosis...952
Abnormal Noise Symptom Diagnosis of A/C System...954
A/C System Performance Inspection...955
A/C System Inspection at ECM...960
Repair Instructions...961
Operation Procedure for Refrigerant Charge...961
Condenser Assembly On-Vehicle Inspection...966
Condenser Assembly Removal and Installation...966
Receiver/Dryer Removal and Installation...967
HVAC Unit Components...968
HVAC Unit Removal and Installation...969
Evaporator Inspection...969
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation...970
Evaporator Thermistor (Evaporator Temperature Sensor) Inspection...970
Expansion Valve Removal and Installation...971
Expansion Valve Inspection...971
A/C Refrigerant Pressure Sensor and Its Circuit Inspection...971
A/C Refrigerant Pressure Sensor Removal and Installation...971
A/C Switch Inspection...972
Compressor Relay Inspection...972
Compressor Drive Belt Inspection and Adjustment...972
Compressor Drive Belt Removal and Installation...973
Compressor Assembly Removal and Installation...973
Compressor Assembly Components...974
Magnet Clutch Inspection...974
Magnet Clutch Removal and Installation...974
Relief Valve Inspection...976
Relief Valve Removal and Installation...977
Specifications...977
Tightening Torque Specifications...977
Special Tools and Equipment...978
Recommended Service Material...978
Special Tool...978
Automatic Type...979
Precautions...979
A/C System Caution...979
Precautions in Diagnosing Trouble...979
Precautions on Servicing A/C System...979
General Description...979
Auto A/C System Description...979
HVAC Control Module Operation Description...981
Refrigerant Type Identification...981
Sub-Cool A/C System Description...981
A/C Operation Description...981
On-Board Diagnostic System Description...982
Schematic and Routing Diagram...982
Major Components of A/C System...982
A/C System Wiring Diagram...983
Diagnostic Information and Procedures...984
A/C System Symptom Diagnosis...984
Abnormal Noise Symptom Diagnosis of A/C System...987
DTC Check...987
DTC Clearance...988
DTC Table...989
Fail-Safe Table...990
Scan Tool Data...991
Air Conditioning System Check...992
Visual Inspection...994
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction...994
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction...995
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction...997
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit Malfunction...998
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit Malfunction...1000
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction...1002
DTC B1514: Air Flow Control Actuator and/or Its Circuit Malfunction...1005
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction...1007
DTC B1546: A/C Refrigerant Pressure Malfunction...1008
DTC B1551: Serial Communication Circuit Malfunction...1008
DTC B1552: Serial Communication Signal Malfunction...1009
DTC B1553: CAN Communication Signal Malfunction...1010
DTC B1557: Vehicle Speed Sensor Signal Malfunction...1010
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunction...1011
DTC B1562: Outside Air Temperature Sensor Signal Malfunction...1011
DTC B1563: A/C Refrigerant Pressure Sensor Signal Malfunction...1011
Inspection of HVAC Control Module and Its Circuit...1012
A/C System Performance Inspection...1015
A/C System Inspection at ECM...1015
Repair Instructions...1016
Operation Procedure for Refrigerant Charge...1016
HVAC Unit Components...1017
HVAC Unit Removal and Installation...1018
Temperature Control Actuator Removal and Installation...1018
Temperature Control Actuator Inspection...1018
Air Flow Control Actuator Removal and Installation...1019
Air Flow Control Actuator Inspection...1019
Air Intake Control Actuator Removal and Installation...1020
Air Intake Control Actuator Inspection...1020
Actuator Linkage Inspection...1021
Blower Motor Controller Removal and Installation...1021
Blower Motor Controller Inspection...1021
HVAC Control Module Removal and Installation...1022
Sunload Sensor Removal and Installation...1022
Sunload Sensor Inspection...1022
Outside Air Temperature Sensor Removal and Installation...1022
Outside Air Temperature Sensor Inspection...1022
Inside Air Temperature Sensor Removal and Installation...1023
Inside Air Temperature Sensor Inspection...1023
Condenser Assembly On-Vehicle Inspection...1023
Condenser Assembly Removal and Installation...1023
Receiver/Dryer Removal and Installation...1023
Evaporator Inspection...1023
Evaporator Temperature Sensor Removal and Installation...1023
Evaporator Temperature Sensor Inspection...1023
Expansion Valve Removal and Installation...1023
Expansion Valve Inspection...1023
A/C Refrigerant Pressure Sensor and Its Circuit Inspection...1023
A/C Refrigerant Pressure Sensor Removal and Installation...1023
Compressor Relay Inspection...1023
Compressor Drive Belt Inspection and Adjustment...1023
Compressor Drive Belt Removal and Installation...1024
Compressor Assembly Removal and Installation...1024
Compressor Assembly Components...1024
Magnet Clutch Removal and Installation...1024
Magnet Clutch Inspection...1024
Relief Valve Inspection...1024
Special Tools and Equipment...1024
Special Tool...1024
Restraint...1026
Precautions...1028
Precautions...1028
Precautions on Restraint...1028
Seat Belts...1029
Precautions...1029
Precautions on Service and Diagnosis of Seat Belt...1029
General Description...1029
Seat Belt Construction...1029
Diagnostic Information and Procedures...1030
Repair and Inspection Required after Accident...1030
Repair Instructions...1031
Front Seat Belt Components...1031
Front Seat Belt Removal and Installation...1032
Front Seat Belt Inspection...1032
Rear Seat Belt Components...1034
Rear Seat Belt Removal and Installation...1035
Rear Seat Belt Inspection...1035
Specifications...1035
Tightening Torque Specifications...1035
Air Bag System...1036
Precautions...1036
Precautions on Service and Diagnosis of Air Bag System...1036
Precautions on Handling and Storage of Air Bag System Components...1037
Precautions on Disposal of Air Bag and Seat Belt Pretensioner...1040
General Description...1040
Air Bag System Construction...1040
Air Bag System Input / Output Table...1041
Schematic and Routing Diagram...1042
Air Bag System Wiring Circuit Diagram...1042
Component Location...1044
Air Bag System Components, Wiring and Connectors Location...1044
Diagnostic Information and Procedures...1045
Air Bag Diagnostic System Check...1045
Air Bag Diagnostic System Check Flow...1045
DTC Table...1046
DTC Check...1047
DTC Clearance...1047
Scan Tool Data...1048
“AIR BAG” Warning Right Comes ON Steady...1048
“AIR BAG” Warning Right Does Not Come ON...1050
“AIR BAG” Warning Right Flashes...1051
DTC B1013: SDM fault...1052
DTC B1014: “AIR BAG” Warning Right Circuit Failure...1052
DTC B1016: Power Source Voltage High...1053
DTC B1017: Power Source Voltage Low...1055
DTC B1021: Front Air Bag Module Deployed...1057
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed...1057
DTC B1026: Pretensioner Activated...1058
DTC B1027: Reusable Number Exceeded...1059
DTC B1031: Driver Air Bag Initiator Circuit Resistance High...1059
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low...1064
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground...1069
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit...1074
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High...1079
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low...1082
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground...1085
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit...1088
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High...1091
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low...1093
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground...1095
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit...1097
DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High...1099
DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low...1102
DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground...1105
DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit...1108
DTC B1071: Forward-Sensor Performance Problem...1111
DTC B1072: Forward-Sensor Communication Error...1111
DTC B1073: Forward-Sensor Circuit Short to Ground...1111
DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open...1113
DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem...1115
DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error...1115
DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground...1115
DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open...1116
DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID...1118
DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High...1119
DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low...1121
DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground...1123
DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit...1125
Contact Coil Cable and Its Circuit Check...1128
Inspection of Intermittent and Poor Connections...1130
Repair and Inspection Required after Accident...1131
Repair Instructions...1133
Disabling Air Bag System...1133
Enabling Air Bag System...1134
SDM Removal and Installation...1135
SDM Inspection...1136
Driver Air Bag (Inflator) Module Removal and Installation...1136
Driver Air Bag (Inflator) Module Inspection...1138
Passenger Air Bag (Inflator) Module Removal and Installation...1138
Passenger Air Bag (Inflator) Module Inspection...1140
Side-Air Bag (Inflator) Module Removal and Installation...1140
Side-Air Bag (Inflator) Inspection...1142
Side Curtain-Air Bag (Inflator) Module Removal and Installation...1142
Side Curtain-Air Bag (Inflator) Module Inspection...1144
Forward-Sensor Removal and Installation...1144
Forward-Sensor Inspection...1145
Side-Sensor Removal and Installation...1145
Side-Sensor Inspection...1146
Passenger Air Bag (Inflator) Module Repair Harness Installation...1147
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal...1148
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal...1159
Specifications...1160
Tightening Torque Specifications...1160
Special Tools and Equipment...1160
Use of Special Tools...1160
Recommended Service Material...1162
Special Tool...1162
Body, Cab and Accessories...1164
Precautions...1168
Precautions...1168
Precautions on Body, Cab and Accessories...1168
Precautions for Body Service...1168
Fastener Caution for Body Service...1168
Wiring Systems...1169
Precautions...1169
Cautions in Body Electrical System Servicing...1169
General Description...1169
Abbreviations...1169
Wire / Connector Color Symbols...1169
Symbols and Marks...1170
How to Read Connector Layout Diagram...1172
How to Read Connector Codes and Terminal Nos...1173
How to Read Ground Point...1175
How to Read Power Supply Diagram...1176
How to Read System Circuit Diagram...1176
Connector Layout Diagram...1178
Connector Layout Diagram...1178
Engine Compartment...1178
Instrument Panel...1184
Door, Roof...1188
Floor...1191
Rear...1197
Ground Point...1198
Ground (earth) Point...1198
Power Supply Diagram...1199
Power Supply Diagram...1199
Fuses and the Protected Parts...1201
Fuses in Main Fuse Box (RHD)...1201
Fuses in Main Fuse Box (LHD)...1201
Individual Circuit Fuse Box No. 1...1202
Individual Circuit Fuse Box No. 2 (In J/B)...1203
Junction Block (J/B) Connector / Fuse Layout...1205
Junction Block Inner Circuit (Overview)...1206
Junction Block Inner Circuit (Detail)...1208
System Circuit Diagram...1213
System Circuit Diagram...1213
A-1 Cranking System Circuit Diagram...1214
A-2 Charging System Circuit Diagram...1215
A-3 Ignition System Circuit Diagram...1216
A-4 Cooling System Circuit Diagram...1217
A-5 Engine and A/C Control System Circuit Diagram...1218
A-6 A/T Control System Circuit Diagram...1223
A-7 Immobilizer System Circuit Diagram...1225
A-8 Body Control System Circuit Diagram...1226
B-1 Windshield Wiper and Washer Circuit Diagram...1230
B-2 Rear Wiper and Washer Circuit Diagram...1231
B-3 Rear Defogger Circuit Diagram...1232
B-4 Power Window Circuit Diagram...1233
B-5 Power Door Lock Circuit Diagram...1235
B-6 Power Mirror Circuit Diagram...1237
B-7 Horn Circuit Diagram...1238
B-8 Seat Heater Circuit Diagram...1239
B-9 Keyless Start System Circuit Diagram...1240
C-1 Combination Meter Circuit Diagram (Meter)...1241
C-2 Combination Meter Circuit Diagram (Indicator)...1242
C-3 Combination Meter Circuit Diagram (Warning Light)...1243
D-1 Headlight System Circuit Diagram...1245
D-2 Position, Tail and Licence Plate Light System Circuit Diagram...1247
D-3 Front Fog Light System Circuit Diagram...1248
D-4 Illumination Light System Circuit Diagram...1249
D-5 Interior Light System Circuit Diagram...1250
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram...1251
D-7 Brake Light System Circuit Diagram...1253
D-8 Back-Up Light System Circuit Diagram...1254
D-9 Headlight Beam Leveling System Circuit Diagram...1255
D-10 Rear Fog Light Circuit Diagram...1256
E-1 Heater System Circuit Diagram...1257
E-2 Auto A/C System Circuit Diagram...1259
F-1 Air-Bag System Circuit Diagram...1261
F-2 Anti-Lock Brake System Circuit Diagram...1263
F-3 Electronic Stability Program System Circuit Diagram...1265
F-4 Power Steering System Circuit Diagram...1267
G-1 Audio System Circuit Diagram...1269
G-2 Multi Information Display / Accessory Socket System Circuit Diagram...1270
List of Connector...1271
List of Connectors...1271
C Connector...1271
D Connector (M16A engine)...1272
E Connector...1272
G Connector...1274
J Connector...1276
K Connector...1277
L Connector...1277
M Connector (SPORT model)...1279
O Connector...1279
R Connector...1279
Lighting Systems...1280
Component Location...1280
Lighting System Components Location...1280
Interior Light System Location...1281
Diagnostic Information and Procedures...1281
Headlight Symptom Diagnosis...1281
Headlight Leveling System Symptom Diagnosis (If Equipped)...1281
Turn Signal and Hazard Warning Light Symptom Diagnosis...1282
Clearance, Tail and License Plate Light Symptom Diagnosis...1282
Back-Up Light Symptom Diagnosis...1283
Brake Light Symptom Diagnosis...1283
Front Fog Light Symptom Diagnosis (If Equipped)...1283
Interior Light Symptom Diagnosis...1284
Repair Instructions...1284
Headlight Housing Removal and Installation...1284
Headlight Bulb Replacement...1285
Headlight Aiming Adjustment with Screen...1285
Headlight Switch (in Lighting Switch) Removal and Installation...1287
Headlight Switch (in Lighting Switch) Inspection...1287
Hazard Warning Switch Removal and Installation...1287
Hazard Warning Switch Inspection...1288
Brake Light Switch Inspection...1288
Turn Signal Light Switch (in Lighting Switch) Removal and Installation...1288
Turn Signal Light Switch (in Lighting Switch) Inspection...1288
Turn Signal and Hazard Warning Relay Removal and Installation...1288
Turn Signal and Hazard Warning Relay Inspection...1289
License Light Removal and Installation...1289
Front Fog Light Removal and Installation (If Equipped)...1290
Front Fog Light Bulb Replacement (If Equipped)...1290
Front Fog Light Switch Inspection (If Equipped)...1290
Front Fog Light Relay Inspection (If Equipped)...1290
Front Fog Light Aiming Adjustment with Screen (If Equipped)...1291
Headlight Leveling Switch Inspection (If Equipped)...1292
Headlight Leveling Actuator Inspection (If Equipped)...1292
Instrumentation / Driver Info. / Horn...1293
Precautions...1293
Precautions in Diagnosing Troubles for Combination Meter...1293
General Description...1293
CAN Communication System Description...1293
Auto Volume Control System Description (If Equipped)...1295
Schematic and Routing Diagram...1296
Combination Meter Circuit Diagram...1296
Component Location...1298
Audio System Component Location...1298
Diagnostic Information and Procedures...1298
Speedometer and VSS Symptom Diagnosis...1298
Tachometer Symptom Diagnosis...1298
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis...1299
Fuel Meter Symptom Diagnosis...1299
Low Fuel Warning Light Symptom Diagnosis...1299
Oil Pressure Warning Light Symptom Diagnosis...1300
Brake and Parking Brake Warning Light Symptom Diagnosis...1300
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)...1300
A/T Shift Position Indicator Symptom Diagnosis (A/T Model)...1301
Charge Warning Light Symptom Diagnosis...1301
Main Beam (High Beam) Indicator Symptom Diagnosis...1301
Warning Buzzer Circuit Symptom Diagnosis...1302
Cigarette Lighter Symptom Diagnosis (If Equipped)...1302
Horn Symptom Diagnosis...1302
Information Display Symptom Diagnosis (If Equipped)...1303
Clock Symptom Diagnosis (If Equipped)...1304
Audio System Symptom Diagnosis (If Equipped)...1304
Remote Audio Control Switch Symptom Diagnosis (If Equipped)...1305
Navigation Symptom Diagnosis (If Equipped)...1306
Repair Instructions...1306
Ignition Switch Removal and Installation...1306
Ignition Switch Inspection...1306
Combination Meter Removal and Installation...1307
Fuel Level Sensor Removal and Installation...1307
Fuel Level Sensor Inspection...1307
Oil Pressure Switch Removal and Installation...1307
Oil Pressure Switch Inspection...1308
Engine Coolant Temperature (ECT) Sensor Inspection...1308
Brake Fluid Level Switch Inspection...1308
Parking Brake Switch Inspection...1308
Door Switch (Front / Rear Door) Inspection...1309
Rear End Door Switch Inspection...1309
Outside Air Temperature Sensor Removal and Installation (If Equipped)...1309
Outside Air Temperature Sensor Inspection (If Equipped)...1309
Instrument Panel Removal and Installation...1310
Information Display (Clock) Removal and Installation...1311
Audio Unit Removal and Installation...1311
Front Speaker Removal and Installation...1311
Rear Speaker Removal and Installation...1312
Horn Removal and Installation...1312
Horn Inspection...1312
Horn Relay Inspection...1312
Antenna Amplifier Removal and Installation...1313
Remote Audio Control Switch Removal and Installation (If Equipped)...1313
Remote Audio Control Switch Inspection (If Equipped)...1314
Vehicle Speed Signal Inspection (For Audio Unit) (If Equipped)...1314
Specifications...1314
Tightening Torque Specifications...1314
Wipers / Washers...1315
Diagnostic Information and Procedures...1315
Front Wiper and Washer Symptom Diagnosis...1315
Rear Wiper and Washer Symptom Diagnosis...1315
Repair Instructions...1316
Wipers and Washers Components...1316
Washer Tank and Washer Pump Removal and Installation...1317
Washer Pump Inspection...1317
Windshield Wiper Removal and Installation...1318
Windshield Wiper Motor Inspection...1319
Rear Wiper Removal and Installation...1320
Rear Wiper Motor Inspection...1321
Windshield Wiper and Washer Switch Removal and Installation...1321
Windshield Wiper and Washer Switch Inspection...1322
Rear Wiper and Washer Switch Removal and Installation...1323
Rear Wiper and Washer Switch Inspection...1323
Rear Wiper Relay Removal and Installation...1324
Rear Wiper Relay Inspection...1324
Specifications...1324
Tightening Torque Specifications...1324
Glass / Windows / Mirrors...1325
General Description...1325
Rear End Door Window Defogger System Description...1325
Windshield Construction...1325
Diagnostic Information and Procedures...1326
Rear End door Window Defogger Symptom Diagnosis...1326
Power Window Control System Symptom Diagnosis...1326
Power Door Mirror Control System Symptom Diagnosis...1327
Door Mirror Heater Symptom Diagnosis (If Equipped)...1327
Repair Instructions...1328
Windshield Removal and Installation...1328
Front Door Window Components...1332
Front Door Glass Removal and Installation...1332
Front Door Window Regulator Removal and Installation...1333
Front Door Window Regulator Inspection...1334
Rear Door Window Components...1334
Rear Door Glass Removal and Installation...1335
Rear Door Window Regulator Removal and Installation...1336
Rear Door Window Regulator Inspection...1336
Rear End Door Window Components...1337
Rear End Door Glass Removal and Installation...1337
Rear End Door Window Defogger Switch Inspection...1338
Rear End Door Window Defogger Relay Inspection...1338
Rear End Door Window Defogger Wire Inspection...1339
Rear End Door Window Defogger Wire Repair...1339
Power Window Main Switch Inspection...1340
Power Window Sub Switch Inspection...1341
Door Mirror Components...1342
Door Mirror Removal and Installation...1342
Power Door Mirror Switch Inspection...1342
Power Door Mirror Actuator Inspection...1343
Door Mirror Heater Switch Inspection (If Equipped)...1343
Door Mirror Heater Inspection (If Equipped)...1343
Special Tools and Equipment...1343
Recommended Service Material...1343
Security and Locks...1344
General Description...1344
Key Coding Construction...1344
Rear End Door Opener System Description...1344
Component Location...1345
Power Door Lock and Keyless Entry System Component Location...1345
Diagnostic Information and Procedures...1346
Power Door Lock System Symptom Diagnosis...1346
Power Door Lock System Operation Inspection...1346
Keyless Entry System Symptom Diagnosis (If Equipped)...1347
Keyless Entry System Operation Inspection...1348
Door Lock Function of Keyless Start System Symptom Diagnosis (If Equipped)...1348
Rear End Door Opener System Symptom Diagnosis...1348
Rear End Door Opener System Operation Inspection...1348
Repair Instructions...1349
Front Door Lock Assembly Components...1349
Front Door Lock Assembly Removal and Installation...1349
Front Door Lock Assembly Inspection...1351
Power Door Lock Switch Inspection...1351
Door Key Cylinder Switch Inspection...1351
Power Door Lock Actuator Inspection...1352
Rear Door Lock Assembly Components...1353
Rear Door Lock Assembly Removal and Installation...1353
Rear Door Lock Assembly Inspection...1353
Rear End Door Lock Assembly Components...1354
Rear End Door Lock Assembly Removal and Installation...1354
Rear End Door Lock Assembly Inspection...1355
Rear End Door Opener Switch Inspection...1355
Replacement of Transmitter Battery...1356
Programming Transmitter Code for Keyless Entry System (Vehicle without Keyless Start System)...1356
Keyless Entry Answer Back Function Change- over Procedure (If Equipped)...1357
Keyless Entry Receiver Removal and Installation...1357
Keyless Entry Receiver and Its Circuit Inspection...1358
Specifications...1359
Tightening Torque Specifications...1359
Special Tools and Equipment...1359
Recommended Service Material...1359
Seats...1360
Repair Instructions...1360
Front Seat Components...1360
Front Seat Removal and Installation...1361
Rear Seat Components...1362
Rear Seat Removal and Installation...1363
Specifications...1363
Tightening Torque Specifications...1363
Special Tools and Equipment...1363
Recommended Service Material...1363
Interior Trim...1364
Repair Instructions...1364
Floor Carpet Removal and Installation...1364
Head Lining Removal and Installation...1364
Console Box Components...1365
Specifications...1366
Tightening Torque Specifications...1366
Hood / Fenders / Doors...1367
Repair Instructions...1367
Hood Removal and Installation...1367
Hood Inspection and Adjustment...1367
Front Fender Components...1368
Front Fender Removal and Installation...1368
Front Door Assembly Components...1369
Front Door Assembly Removal and Installation...1369
Rear Door Assembly Components...1371
Rear Door Assembly Removal and Installation...1371
Rear End Door Assembly Components...1372
Rear End Door Assembly Removal and Installation...1372
Specifications...1374
Tightening Torque Specifications...1374
Special Tools and Equipment...1374
Recommended Service Material...1374
Body Structure...1375
Repair Instructions...1375
Front Bumper and Rear Bumper Components...1375
Cowl Top Components...1376
Specifications...1377
Body Dimensions...1377
Panel Clearance...1384
Paint / Coatings...1385
General Description...1385
Anti-Corrosion Treatment Construction...1385
Plastic Parts Finishing...1386
Component Location...1387
Sealant Application Areas...1387
Under Coating Application Areas...1392
Anti-Corrosion Compound Application Area...1394
Exterior Trim...1395
Repair Instructions...1395
Roof Molding Components...1395
Splash Guard (If Equipped) Components...1396
Control Systems...1398
Precautions...1400
Precautions...1400
Precautions for Control Systems...1400
Body Electrical Control System...1401
Precautions...1401
Precautions in Diagnosing Trouble...1401
General Description...1401
BCM General Description...1401
CAN Communication System Description...1402
Theft Deterrent Light...1403
Security Alarm Description (If Equipped)...1403
Schematic and Routing Diagram...1404
Body Electrical Control System Wiring Circuit Diagram...1404
Connector Layout Diagram of BCM and Junction Block Assembly...1407
Component Location...1408
BCM and Related System Component Location...1408
Diagnostic Information and Procedures...1409
BCM Self-Diagnosis Function...1409
Body Electrical Control System Check...1410
Scan Tool Data...1412
DTC Table...1414
DTC Check...1414
DTC Clearance...1415
BCM Power Circuit and Ground Circuit Check...1416
DTC B1133 (DTC No. 1133): Battery Voltage Too High...1417
DTC B1141 / DTC B1142 (No. 1141 / No. 1142): Outside Air Temperature (Ambient Temp.) Sensor Circuit Malfunction...1418
DTC B1150 (No. 1150): Air Bag Communication Circuit Malfunction...1419
DTC B1157 (No. 1157): Air Bag Deployment Signal Input...1420
DTC B1170 (No. 1170): EEPROM Access Error...1421
DTC U0155 (No. 0155): Lost Communication with Instrument Panel Cluster (IPC) Control Module...1421
DTC U1073 (No. 1073): Control Module Communication Bus Off...1424
DTC U1100 (No. 1100): Lost Communication with ECM...1425
DTC U1101 (No. 1101): Lost Communication with TCM...1427
DTC U1144 (No. 1144): Lost Communication with Keyless Start Control Module...1429
Inspection of BCM and its Circuits...1431
Repair Instructions...1439
BCM (Included in Junction Block Assembly) Removal and Installation...1439
Outside Air Temperature Sensor Removal and Installation...1439
Outside Air Temperature Sensor Inspection...1439
Security Alarm Mode Selection Procedure (If Equipped)...1439
Special Tools and Equipment...1440
Special Tool...1440
Immobilizer Control System...1441
Precautions...1441
Precautions in Diagnosing Troubles...1441
Precaution in Replacing ECM...1441
Precautions in Handling Immobilizer Control System...1441
General Description...1442
Immobilizer Control System Introduction...1442
Immobilizer Control System Components Location...1443
On-Board Diagnostic System Description (Self-diagnosis Function)...1443
Schematic and Routing Diagram...1444
Immobilizer Control System Wiring Circuit Diagram...1444
Diagnostic Information and Procedures...1445
Immobilizer Control System Check...1445
Diagnostic Trouble Code (DTC) Check...1445
Diagnostic Trouble Code (DTC) Clearance...1446
Diagnostic Trouble Code (DTC) Table...1446
Scan Tool Data...1447
Immobilizer Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop...1447
Immobilizer Indicator Lamp Remains ON after Engine Starts...1448
DTC P1614: Transponder Response Error...1449
DTC P1615: ID Code Does Not Registered (Vehicle equipped with keyless start system only)...1449
DTC P1616: Different Registration ID Codes (Vehicle equipped with keyless start system only)...1450
DTC P1618: CAN Communication Error (Reception Error for Keyless Start Control Module) (Vehicle equipped with keyless start system only)...1451
DTC P1621: Immobilizer Communication Line Error...1452
DTC P1622: EEPROM Reading / Writing Error...1453
DTC P1623: Unregistered Transponder...1453
DTC P1625: Immobilizer Antenna Error...1454
DTC P1636: Immobilizer Information Registration Failure...1454
DTC P1638: Immobilizer Information Mismatched...1455
Inspection of Immobilizer Control Module (ICM) and Its Circuit...1456
Repair Instructions...1458
Immobilizer Control Module (ICM) Removal and Installation...1458
Registration of the Ignition Key...1458
Procedure after ECM Replacement...1458
Special Tools and Equipment...1459
Special Tool...1459
Keyless Start System...1460
General Description...1460
Keyless Start System Description...1460
Parts and Functions...1461
Keyless Engine Start Function...1462
Door Lock Function of Keyless Start System...1463
Operation Area of Remote Controller...1464
Alarm Function...1465
CAN Communication System Description...1465
Schematic and Routing Diagram...1466
Keyless Start System Electric Wiring Circuit Diagram...1466
Diagnostic Information and Procedures...1467
Precautions in Diagnosing Troubles...1467
Self-Diagnosis Function...1467
Keyless Start System Diagnosis Introduction...1467
Keyless Start System Check...1467
Customer Questionnaire (Example)...1468
Key Indicator Lamp Check...1469
DTC Check...1469
DTC Table...1470
DTC Clearance...1471
Keyless Start System Symptom Diagnosis...1471
Keyless Start System Operation Inspection...1472
Door Lock Operation (Keyless Start System)...1473
Inspection of Keyless Start Control Module and Its Circuits...1473
No DTC Detection After Performing DTC Check...1477
Key Indicator Lamp Circuit Check (Key indicator lamp doesn’t light when ignition knob switch is pushed.)...1479
Keyless Start Control Module Power and Ground Circuit Check...1481
DTC No. 11: Communication Error with Steering Lock Unit...1482
DTC No. 13 / No. 14: Release Signal Error from Steering Lock Unit / Steering Lock Unit Malfunction...1483
DTC No. 21 / No. 22: Internal Error of Keyless Start Control Module (EEPROM reading error) / (EEPROM writing error)...1483
DTC No. 31: Lost Communication with BCM...1484
DTC No. 33: Control Module Communication Bus Off...1486
DTC No. 51 / No. 52 / No. 53: Driver Side / Passenger Side / Rear End Door Request Switch Failure...1487
Repair Instructions...1489
Antennas and Request Switches Removal and Installation...1489
Front Door (Driver and Passenger Side), Rear End Door Request Switch Inspection...1490
Steering Lock Unit Removal and Installation...1490
Steering Lock Unit Inspection...1490
Front Door Lock Switch Inspection...1490
Keyless Start Control Module Removal and Installation...1491
Remote Controller Inspection...1491
Replacement of Remote Controller Battery...1491
Registration Procedure for Remote Controller ID Code...1492
Suzuki Swift, Swift Sport Repair Service Manual 1988-2010
