Suzuki Swift Sport RS415 Service Manual – PDF DOWNLOAD
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DESCRIPTION:
Suzuki Swift Sport RS415 Service Manual – PDF DOWNLOAD
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
, and NOTE have special meanings. Pay special attention to the messages highlighted
by these signal word
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
- Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.
- If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
- Do not modify the steering wheel, instrument panel or any other air bag system component on or around air bag system components or wiring. Modifications can adversely affect air bag system performance and lead to injury.
- If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation.
FOREWORD
- This manual (Volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul). - VOLUME 1 contains General information, Engine, Suspension, Drive/Axle and Brakes sections (Sections 0 – 4).
VOLUME 2 contains Transmmision/Transaxle, Steering, HVAC, Restraint, Body/Cab/Accessories and
Control Systems sections (Sections 5 – 10). - Applicable model:
SWIFT (RS415) vehicles on and after following vehicle identification numbers (VINs).
JSAEZC21S00100001
- The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
- This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
- When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
- All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval.
- And used as the main subject of description is the vehicle of standard specifications among others.
- Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice.
TABLE OF CONTENTS:
Suzuki Swift Sport RS415 Service Manual – PDF DOWNLOAD
TOP 0
MANUAL LIST 0
IMPORTANT 1
FOREWORD 3
TABLE OF CONTENTS 5
Precautions 7
Precautions 8
Precautions 8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System 8
General Precautions 10
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 25
Engine Supporting Points 27
Vehicle Identification Number 28
Engine Identification Number 28
Transmission Identification Number 28
Component Location 28
Warning, Caution and Information Labels Location 28
Maintenance and Lubrication 30
Precautions 30
Precautions for Maintenance and Lubrication 30
Scheduled Maintenance 30
Maintenance Schedule under Normal Driving Conditions 30
Maintenance Recommended under Severe Driving Conditions 31
Repair Instructions 32
Accessory Drive Belt Inspection 32
Accessory Drive Belt Replacement 33
Valve Lash (Clearance) Inspection 33
Engine Oil and Filter Change 33
Engine Coolant Change 34
Exhaust System Inspection 35
Spark Plugs Replacement 35
Air Cleaner Filter Inspection 35
Air Cleaner Filter Replacement 35
Fuel Lines and Connections Inspection 35
Fuel Filter Replacement 36
Fuel Tank Inspection 36
PCV Valve Inspection 36
Fuel Evaporative Emission Control System Inspection 36
Brake Discs and Pads (Front) Inspection 36
Brake Drums and Shoes (Rear) Inspection 36
Brake Hoses and Pipes Inspection 37
Brake Fluid Replacement 37
Brake Lever and Cable Inspection 37
Clutch fluid Inspection 37
Tires Inspection 38
Wheel Discs Inspection 38
Wheel Bearing Inspection 38
Suspension System Inspection 38
Steering System Inspection 38
Drive Shaft (Axle) Boots Inspection 39
Manual Transaxle Oil Inspection 39
Manual Transaxle Oil Replacement 39
Automatic Transaxle Fluid Level Inspection 40
Automatic Transaxle Fluid Replacement 40
Automatic Transaxle Fluid Cooler Hose Inspection 40
All Latches, Hinges and Locks Inspection 40
Air Conditioning Filter (If Equipped) Inspection 41
Air Conditioning Filter (If Equipped) Replacement 41
Final Inspection for Maintenance Service 41
Specifications 42
Tightening Torque Specifications 42
Special Tools and Equipment 42
Recommended Fluids and Lubricants 42
Special Tool 42
Engine 43
Precautions 48
Precautions 48
Precautions for Engine 48
Engine General Information and Diagnosis 49
Precautions 49
Precautions on Engine Service 49
Precautions in Diagnosing Trouble 49
Precautions of ECM Circuit Inspection 49
General Description 50
Statement on Cleanliness and Care 50
Engine Diagnosis General Description 50
On-Board Diagnostic System Description 50
Engine and Emission Control System Description 53
CAN Communication System Description 53
Air Intake System Description 54
Electronic Control System Description 55
Engine and Emission Control Input / Output Table 61
Schematic and Routing Diagram 62
Engine and Emission Control System Diagram 62
Component Location 63
Electronic Control System Components Location 63
Diagnostic Information and Procedures 64
Engine and Emission Control System Check 64
Malfunction Indicator Lamp (MIL) Check 67
DTC Check 67
DTC Clearance 68
DTC Table 68
Fail-Safe Table 72
Scan Tool Data 72
Visual Inspection 76
Engine Basic Inspection 77
Engine Symptom Diagnosis 80
Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started) 86
Malfunction Indicator Lamp Remains ON after Engine Starts 88
DTC P0010: Camshaft Position Actuator Circuit 90
DTC P0011 / P0012: Camshaft Position – Timing Over-Advanced or System Performance / -Retarded 92
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1) 94
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2) 96
DTC P0101: Mass Air Flow Circuit Range / Performance 98
DTC P0102: Mass Air Flow Circuit Low Input 102
DTC P0103: Mass Air Flow Circuit High Input 104
DTC P0106: Manifold Absolute Pressure Range / Performance 106
DTC P0107: Manifold Absolute Pressure Circuit Low Input 108
DTC P0108: Manifold Absolute Pressure Circuit High Input 110
DTC P0111: Intake Air Temperature Circuit Range / Performance 112
DTC P0112: Intake Air Temperature Sensor Circuit Low 115
DTC P0113: Intake Air Temperature Sensor Circuit High 118
DTC P0116: Engine Coolant Temperature Circuit Range / Performance 121
DTC P0117: Engine Coolant Temperature Circuit Low 124
DTC P0118: Engine Coolant Temperature Circuit High 126
DTC P0121: Throttle Position Sensor Circuit Range / Performance 128
DTC P0122: Throttle Position Sensor Circuit Low 133
DTC P0123: Throttle Position Sensor Circuit High 136
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-1) 139
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1) 142
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-1) 143
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2) 146
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2) 149
DTC P0171 / P0172: Fuel System Too Lean / Rich 151
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected 153
DTC P0327 / P0328: Knock Sensor Circuit Low / High 155
DTC P0335: Crankshaft Position (CKP) Sensor Circuit 157
DTC P0340: Camshaft Position (CMP) Sensor Circuit 159
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected 162
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 P0462: Fuel Level Sensor Circuit Low 171
DTC P0463: Fuel Level Sensor Circuit High 173
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit 175
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction 179
DTC P0505: Idle Air Control System 182
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low 184
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High 186
DTC P0601 / P0602: Internal Control Module Memory Check Sum Error / Control Module Programming Error 188
DTC P0616: Starter Relay Circuit Low 189
DTC P0617: Starter Relay Circuit High 190
DTC P1510: ECM Back-Up Power Supply Malfunction 192
DTC P1603: TCM Trouble Code Detected 193
DTC P1674: CAN Communication (Bus Off Error) 194
DTC P1675: CAN Communication (Transmission Error) 198
DTC P1676: CAN Communication (Reception Error for TCM) 201
DTC P1678: CAN Communication (Reception Error for BCM) 204
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction 206
Inspection of ECM and Its Circuits 208
ECM Power and Ground Circuit Check 225
Fuel Injector Circuit Check 228
Fuel Pump and Its Circuit Check 230
Fuel Pressure Check 233
Idle Air Control System Check 234
A/C System Circuits Check 236
Electric Load Signal Circuit Check 240
Radiator cooling fan Low Speed Control System Check 241
Radiator cooling fan High Speed Control System Check 243
Repair Instructions 246
Idle Speed / Idle Air Control (IAC) Duty Inspection 246
Special Tools and Equipment 247
Special Tool 247
Aux Emission Control Devices 248
Diagnostic Information and Procedures 248
EGR System Inspection 248
Repair Instructions 248
EVAP Canister Purge Inspection 248
EVAP Canister Purge Valve and Its Circuit Inspection 248
Vacuum Passage Inspection 249
Vacuum Hose Inspection 250
EVAP Canister Purge Valve Inspection 250
EVAP Canister Inspection 250
EGR Valve Removal and Installation 251
EGR Valve Inspection 251
PCV Hose Inspection 251
PCV Valve Inspection 251
Special Tools and Equipment 252
Special Tool 252
Engine Electrical Devices 253
Repair Instructions 253
Idle Air Control (IAC) Valve Operation Inspection 253
Idle Air Control (IAC) Valve On-Vehicle Inspection 253
Idle Air Control (IAC) Valve Removal and Installation 254
Engine Control Module (ECM) Removal and Installation 254
Manifold Absolute Pressure (MAP) Sensor Inspection 255
Throttle Position (TP) Sensor On-Vehicle Inspection 255
Throttle Position (TP) Sensor Removal and Installation 256
Engine Coolant Temperature (ECT) Sensor Removal and Installation 256
Engine Coolant Temperature (ECT) Sensor Inspection 257
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Heater On-Vehicle Inspection 257
Heated Oxygen Sensor (HO2S-1 and HO2S-2) Removal and Installation 257
Camshaft Position (CMP) Sensor Removal and Installation 258
Camshaft Position (CMP) Sensor Inspection 258
Crankshaft Position (CKP) Sensor Removal and Installation 259
Crankshaft Position (CKP) Sensor Inspection 259
Vehicle Speed Sensor (VSS) Inspection (M/T model) 260
Knock Sensor Removal and Installation 260
Main Relay, Fuel Pump Relay, Starting Motor Control Relay and Throttle Actuator Control Relay Inspection 261
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection 261
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation 262
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection 262
Specifications 263
Tightening Torque Specifications 263
Special Tools and Equipment 263
Special Tool 263
Engine Mechanical 264
General Description 264
Engine Construction Description 264
Camshaft Position Control (VVT Variable Valve Timing) System Description 264
Diagnostic Information and Procedures 267
Compression Check 267
Engine Vacuum Check 268
Valve Lash (Clearance) Inspection 269
Repair Instructions 271
Air Cleaner Element Removal and Installation 271
Air Cleaner Element Inspection and Cleaning 272
Cylinder Head Cover Removal and Installation 272
Accelerator Cable Adjustment 274
Throttle Body Components 274
Throttle Body On-Vehicle Inspection 275
Throttle Body Removal and Installation 275
Throttle Body Cleaning 276
Throttle Body and Intake Manifold Components 277
Intake Manifold Removal and Installation 278
Engine Mountings Components 279
Engine Assembly Removal and Installation 280
Timing Chain Cover Components 283
Timing Chain Cover Removal and Installation 284
Timing Chain Cover Inspection 286
Oil Control Valve Removal and Installation 286
Oil Control Valve Inspection 287
Timing Chain and Chain Tensioner Components 287
Timing Chain and Chain Tensioner Removal and Installation 288
Timing Chain and Chain Tensioner Inspection 290
Camshaft, Tappet and Shim Components 291
Camshaft, Tappet and Shim Removal and Installation 292
Camshaft, Tappet and Shim Inspection 294
Valves and Cylinder Head Components 297
Valves and Cylinder Head Removal and Installation 298
Valves and Cylinder Head Disassembly and Assembly 300
Valves and Valve Guides Inspection 302
Cylinder Head Inspection 305
Valve Spring Inspection 305
Pistons, Piston Rings, Connecting Rods and Cylinders Components 306
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation 307
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly 308
Cylinders, Pistons and Piston Rings Inspection 309
Piston Pins and Connecting Rods Inspection 311
Crank Pin and Connecting Rod Bearings Inspection 312
Main Bearings, Crankshaft and Cylinder Block Components 316
Main Bearings, Crankshaft and Cylinder Block Removal and Installation 317
Crankshaft Inspection 319
Main Bearings Inspection 321
Sensor Plate Inspection 326
Rear Oil Seal Inspection 326
Flywheel Inspection 326
Cylinder Block Inspection 326
Specifications 327
Tightening Torque Specifications 327
Special Tools and Equipment 328
Recommended Service Material 328
Special Tool 328
Engine Lubrication System 330
General Description 330
Engine Lubrication Description 330
Diagnostic Information and Procedures 332
Oil Pressure Check 332
Repair Instructions 333
Oil Pan and Oil Pump Strainer Components 333
Oil Pan and Oil Pump Strainer Removal and Installation 334
Oil Pan and Oil Pump Strainer Cleaning 335
Oil Pump Components 336
Oil Pump Removal and Installation 336
Oil Pump Disassembly and Reassembly 336
Oil Pump Inspection 337
Specifications 339
Tightening Torque Specifications 339
Special Tools and Equipment 339
Recommended Service Material 339
Special Tool 339
Engine Cooling System 340
General Description 340
Cooling System Description 340
Coolant Description 340
Schematic and Routing Diagram 341
Coolant Circulation 341
Diagnostic Information and Procedures 342
Engine Cooling Symptom Diagnosis 342
Repair Instructions 343
Cooling System Components 343
Coolant Level Check 344
Engine Cooling System Inspection and Cleaning 344
Cooling System Draining 344
Cooling System Flush and Refill 345
Cooling Water Pipes or Hoses Removal and Installation 346
Thermostat Removal and Installation 346
Thermostat Inspection 347
Radiator Cooling Fan Motor On-Vehicle Inspection 347
Radiator Cooling Fan Relay Inspection 348
Radiator Cooling Fan Removal and Installation 348
Radiator On-Vehicle Inspection and Cleaning 348
Radiator Removal and Installation 349
Water Pump / Generator Drive Belt Tension Inspection and Adjustment 349
Water Pump / Generator Drive Belt Removal and Installation 350
Water Pump Removal and Installation 350
Water Pump Inspection 351
Specifications 351
Tightening Torque Specifications 351
Special Tools and Equipment 351
Recommended Service Material 351
Fuel System 352
Precautions 352
Precautions on Fuel System Service 352
General Description 352
Fuel System Description 352
Fuel Delivery System Description 352
Fuel Pump Description 353
Schematic and Routing Diagram 353
Fuel Delivery System Diagram 353
Diagnostic Information and Procedures 353
Fuel Pressure Inspection 353
Fuel Cut Operation Inspection 354
Repair Instructions 355
Fuel System Components 355
Fuel Hose Disconnecting and Reconnecting 356
Fuel Pressure Relief Procedure 358
Fuel Leakage Check Procedure 358
Fuel Lines On-Vehicle Inspection 358
Fuel Pipe Removal and Installation 358
Fuel Injector On-Vehicle Inspection 359
Fuel Injector Removal and Installation 359
Fuel Injector Inspection 360
Fuel Filler Cap Inspection 361
Fuel Tank Inlet Valve Removal and Installation 362
Fuel Tank Inlet Valve Inspection 363
Fuel Tank Removal and Installation 363
Fuel Tank Inspection 364
Fuel Tank Purging Procedure 364
Fuel Pump On-Vehicle Inspection 365
Fuel Pump Assembly Removal and Installation 365
Fuel Level Sensor Removal and Installation 366
Fuel Pump Inspection 367
Specifications 367
Tightening Torque Specifications 367
Special Tools and Equipment 368
Special Tool 368
Ignition System 369
General Description 369
Ignition System Construction 369
Schematic and Routing Diagram 370
Ignition System Wiring Circuit Diagram 370
Component Location 371
Ignition System Components Location 371
Diagnostic Information and Procedures 372
Ignition System Symptom Diagnosis 372
Reference Waveform of Ignition System 372
Ignition System Check 373
Ignition Spark Test 374
Repair Instructions 375
High-Tension Cord Removal and Installation 375
High-Tension Cord Inspection 375
Spark Plug Removal and Installation 376
Spark Plug Inspection 376
Ignition Coil Assembly (Including ignitor) Removal and Installation 376
Ignition Coil Assembly (Including ignitor) Inspection 377
Ignition Timing Inspection 377
Specifications 378
Tightening Torque Specifications 378
Special Tools and Equipment 378
Special Tool 378
Starting System 379
Schematic and Routing Diagram 379
Cranking System Circuit Diagram 379
Diagnostic Information and Procedures 379
Cranking System Symptom Diagnosis 379
Cranking System Test 381
Repair Instructions 382
Starting Motor Dismounting and Remounting 382
Starting Motor Components 383
Starting Motor Inspection 384
Specifications 387
Cranking System Specifications 387
Tightening Torque Specifications 387
Special Tools and Equipment 387
Recommended Service Material 387
Charging System 388
General Description 388
Battery Description 388
Generator Description 389
Diagnostic Information and Procedures 390
Battery Inspection 390
Generator Symptom Diagnosis 390
Generator Test (Undercharged Battery Check) 391
Generator Test (Overcharged Battery Check) 392
Repair Instructions 393
Jump Starting in Case of Emergency 393
Battery Dismounting and Remounting 393
Generator Dismounting and Remounting 394
Generator Components 395
Generator Inspection 396
Specifications 398
Charging System Specifications 398
Tightening Torque Specifications 398
Exhaust System 399
General Description 399
Exhaust System Description 399
Diagnostic Information and Procedures 399
Exhaust System Check 399
Repair Instructions 400
Exhaust System Components 400
Exhaust Manifold Removal and Installation 401
Exhaust Pipe and Muffler Removal and Installation 402
Specifications 403
Tightening Torque Specifications 403
Suspension 405
Precautions 407
Precautions 407
Precautions on Suspension 407
Suspension General Diagnosis 408
Diagnostic Information and Procedures 408
Suspension, Wheels and Tires Symptom Diagnosis 408
Specifications 410
Wheel Alignment Specifications 410
Front Suspension 411
General Description 411
Front Suspension Construction 411
Front Wheel Alignment Construction 412
Repair Instructions 412
Front Wheel Alignment Inspection and Adjustment 412
Front Strut Assembly Components 414
Front Strut Assembly Removal and Installation 414
Front Strut Assembly Disassembly and Assembly 416
Front Strut Assembly Check 417
Front Wheel Hub and Steering Knuckle Components 418
Front Wheel Hub, Steering Knuckle and Wheel Bearing Removal and Installation 418
Front Wheel Hub, Disc, Nut and Bearing Check 422
Suspension Control Arm / Bushing Removal and Installation 422
Suspension Control Arm / Bushing Disassembly and Assembly 423
Suspension Control Arm / Steering Knuckle Check 424
Suspension Control Arm Bushing Check 424
Suspension Control Arm Joint Check 424
Front Suspension Frame, Stabilizer Bar and/or Bushings Components 425
Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation 425
Front Suspension Frame Check 428
Front Stabilizer Bar, Bushing and/or Joint Check 429
Front Suspension Fasteners Check 429
Specifications 429
Tightening Torque Specifications 429
Special Tools and Equipment 430
Special Tool 430
Rear Suspension 431
General Description 431
Rear Suspension Construction 431
Component Location 432
Rear Suspension Component Location 432
Repair Instructions 433
Rear Shock Absorber Removal and Installation 433
Rear Shock Absorber Inspection 434
Rear Shock Absorber Bush Removal and Installation 434
Rear Shock Absorber Bush Inspection 435
Coil Spring Removal and Installation 435
Spring Upper Seat / Spring Lower Seat Inspection 436
Spring Upper Seat and Lower Seat Removal and Installation 436
Rear Axle Removal and Installation 437
Trailing Arm, Rear Axle and Coil Spring Inspection 440
Rear Axle Bush Inspection 440
Wheel Bearing and Wheel Stud Bolt Removal and Installation 441
Rear Wheel Disc, Nut and Bearing Inspection 442
Spindle Removal and Installation 442
Spindle Inspection 443
Rear Suspension Fasteners Inspection 443
Specifications 444
Tightening Torque Specifications 444
Special Tools and Equipment 444
Special Tool 444
Wheels and Tires 445
General Description 445
Tires Description 445
Wheels Description 446
Irregular and/or Premature Wear Description 446
Wear Indicators Description 447
Radial Tire Waddle Description 447
Radial Tire Lead / Pull Description 448
Balancing Wheels Description 448
Repair Instructions 449
General Balance Procedures 449
Tire Rotation 449
Wheel Removal and Installation 450
Tire Mounting and Dismounting 450
Tire Repair 450
Specifications 451
Wheels and Tires Specifications 451
Tightening Torque Specifications 451
Driveline / Axle 453
Drive Shaft / Axle 454
General Description 454
Front Drive Shaft Construction 454
Component Location 454
Front Drive Shaft Assembly Components Location 454
Diagnostic Information and Procedures 455
Front Drive Shaft Symptom Diagnosis 455
Repair Instructions 455
Front Drive Shaft Components 455
Front Drive Shaft Assembly On-Vehicle Inspection 456
Front Drive Shaft Assembly Removal and Installation 456
Front Drive Shaft Disassembly and Assembly 457
Center Shaft and Center Bearing Support Disassembly and Assembly 460
Front Drive Shaft Inspection 462
Specifications 462
Tightening Torque Specifications 462
Special Tools and Equipment 463
Recommended Service Material 463
Special Tool 463
Brakes 465
Precautions 467
Precautions 467
Precautions for Brakes 467
Brake Control System and Diagnosis 468
Precautions 468
Precautions on Brake 468
General Description 468
Brakes Construction 468
Front Brake Hose / Pipe Construction 469
Rear Brake Hose / Pipe Construction 470
Diagnostic Information and Procedures 470
Brakes Diagnosis Note 470
Brakes Symptom Diagnosis 471
Repair Instructions 473
Brake Pedal Free Height Inspection 473
Brake Pedal Play Inspection 473
Excessive Pedal Travel Inspection 473
Master Cylinder and Brake Fluid Level Inspection 474
Stop Light Switch Adjustment 474
Air Bleeding of Brake System 474
Front Brake Hose / Pipe Removal and Installation 475
Rear Brake Hose / Pipe Removal and Installation 476
Brake Hose and Pipe Inspection 476
Master Cylinder Components 476
Master Cylinder Reservoir Removal and Installation 477
Master Cylinder Assembly Removal and Installation 478
Master Cylinder Assembly Disassembly and Assembly 479
Master Cylinder Assembly Inspection 480
Brake Booster Components 480
Booster Operation Inspection 481
Brake Booster Removal and Installation 482
Brake Booster Inspection and Adjustment 483
Specifications 483
Tightening Torque Specifications 483
Special Tools and Equipment 483
Recommended Service Material 483
Front Brakes 484
Repair Instructions 484
Front Disc Brake Components 484
Front Disc Brake Pad On-Vehicle Inspection 485
Front Disc Brake Pad Removal and Installation 485
Front Disc Brake Pad Inspection 486
Front Disc Brake Caliper Removal and Installation 486
Front Disc Brake Caliper Disassembly and Assembly 487
Front Disc Brake Caliper Inspection 489
Front Brake Disc Removal and Installation 489
Front Brake Disc Inspection 490
Specifications 491
Tightening Torque Specifications 491
Special Tools and Equipment 491
Recommended Service Material 491
Special Tool 491
Rear Brakes 492
Repair Instructions 492
Rear Drum Brake Components 492
Rear Brake Drum Removal and Installation 492
Rear Brake Drum and Shoe Inspection 494
ABS Sensor Ring Removal and Installation (If Equipped) 494
ABS Sensor Ring Inspection 495
Rear Brake Shoe Removal and Installation 495
Rear Brake Shoe Inspection 496
Wheel Cylinder Removal and Installation 496
Wheel Cylinder Inspection 497
Brake Back Plate Removal and Installation 497
Specifications 499
Tightening Torque Specifications 499
Special Tools and Equipment 499
Recommended Service Material 499
Special Tool 499
Parking Brake 500
General Description 500
Parking Brake Cable Construction 500
Repair Instructions 501
Parking Brake Inspection and Adjustment 501
Parking Brake Cable Removal and Installation 502
Parking Brake Lever Removal and Installation 502
Specifications 503
Tightening Torque Specifications 503
ABS 504
Precautions 504
Precautions in Diagnosing Troubles 504
Precautions in On-Vehicle Service 504
General Description 505
ABS Description 505
ABS Hydraulic Unit / Control Module Assembly Description 505
Schematic and Routing Diagram 506
ABS Schematic 506
ABS Wiring Circuit Diagram 507
Component Location 508
ABS Components Location 508
Front Wheel Speed Sensor Components Location 509
Rear Wheel Speed Sensor Components Location 509
Diagnostic Information and Procedures 510
ABS Check 510
ABS Warning Lamp Check 512
EBD Warning Lamp (Brake Warning Lamp) Check 512
DTC Check 512
DTC Table 513
DTC Clearance 513
Scan Tool Data 513
ABS Warning Lamp Does Not Come ON at Ignition Switch ON 514
ABS Warning Lamp Comes ON Steady 515
ABS Warning Lamp Flashes Continuously while Ignition Switch Is ON 517
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady 518
Serial Data Link Circuit Check 519
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right- Rear / Left-Rear Wheel Speed Sensor Circuit or Sensor Ring 521
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 523
DTC C1057: Power Source Circuit 524
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit 525
DTC C1063: Solenoid Valve Power Supply Driver Circuit 526
DTC C1071: ABS Control Module 527
Repair Instructions 528
ABS Hydraulic Unit Operation Check 528
ABS Hydraulic Unit / Control Module Assembly Components 528
ABS Hydraulic Unit / Control Module Assembly On-Vehicle Inspection 529
ABS Hydraulic Unit / Control Module Assembly Removal and Installation 529
Front Wheel Speed Sensor On-Vehicle Inspection 531
Front Wheel Speed Sensor Removal and Installation 531
Front Wheel Speed Sensor Inspection 532
Rear Wheel Speed Sensor On-Vehicle Inspection 532
Rear Wheel Speed Sensor Removal and Installation 533
Rear Wheel Speed Sensor Inspection 534
Front Wheel Speed Sensor Ring On-Vehicle Inspection 534
Front Wheel Speed Sensor Ring Removal and Installation 535
Rear Wheel Speed Sensor Ring On-Vehicle Inspection 535
Rear Wheel Speed Sensor Ring Removal and Installation 535
Specifications 535
Tightening Torque Specifications 535
Special Tools and Equipment 536
Special Tool 536
Transmission / Transaxle 537
Precautions 540
Precautions 540
Precautions on Transmission / Transaxle 540
Automatic Transmission 541
Precautions 541
Precautions in Diagnosing Trouble 541
Precautions for Disassembly and Reassembly 541
General Description 543
A/T Description 543
Clutch / Brake / Planetary Gear Function of Automatic Transaxle 546
Table of Component Operation 546
A/T Diagnosis General Description 547
On-Board Diagnostic System Description 547
CAN Communication System Description 548
Schematic and Routing Diagram 549
Transmission Control Module (TCM) Wiring Diagram 549
Automatic Gear Shift Table 551
Component Location 552
Electronic Shift Control System Components Location 552
Diagnostic Information and Procedures 554
A/T System Check 554
Visual Inspection 557
Malfunction Indicator Lamp (MIL) Check 557
DTC Table 557
DTC Check 559
DTC Clearance 559
Fail-Safe Table 560
Scan Tool Data 562
A/T Basic Check 565
Road Test 566
Manual Road Test 568
Engine Brake Test 569
Stall Test 569
Time Lag Test 571
Line Pressure Test 572
“P” Range Test 573
A/T Symptom Diagnosis 573
No Gear Shift to 4th gear 581
No Lock-Up Occurs 582
DTC P0705: Transmission Range Sensor Circuit Malfunction 583
DTC P0707: Transmission Range Sensor Circuit Low 585
DTC P0712: Transmission Fluid Temperature Sensor Circuit Low 587
DTC P0713: Transmission Fluid Temperature Sensor Circuit High 588
DTC P0717: Input / Turbine Speed Sensor Circuit Malfunction 589
DTC P0722: Output Speed Sensor (VSS) Circuit No Signal 591
DTC P0741 / P0742: TCC Circuit Performance or Stuck OFF / TCC Circuit Stuck ON 593
DTC P0751 / P0752 / P0756 / P0757: Shift Solenoid Malfunction 594
DTC P0787: Shift / Timing Solenoid Control Circuit Low 595
DTC P0788: Shift / Timing Solenoid Control Circuit High 597
DTC P0962: Pressure Control Solenoid Control Circuit Low 599
DTC P0963: Pressure Control Solenoid Control Circuit High 601
DTC P0973 / P0976: Shift Solenoid-A (No1) Control Circuit Low / Shift Solenoid-B (No2) Control Circuit Low 603
DTC P0974 / P0977: Shift Solenoid-A (No1) / Shift Solenoid-B (No2) Control Circuit High 605
DTC P1702: Internal Control Module Memory Check Sum Error 607
DTC P1703: Can Invalid Data – TCM 607
DTC P1723: Range Select Switch Malfunction 608
DTC P1774: Control Module Communication Bus Off 609
DTC P1775: High Speed CAN Communication Bus Off (Transmission Error) 612
DTC P1777: TCM Lost Communication with ECM (Reception Error) 615
DTC P1778: TCM Lost Communication with BCM (Reception Error) 618
DTC P1878: Torque Converter Clutch Shudder 621
DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Control Circuit High 622
DTC P2764: Torque Converter Clutch (TCC) Circuit Pressure Control Solenoid Control Circuit Low 624
Inspection of TCM and Its Circuits 626
TCM Power and Ground Circuit Check 630
Brake Interlock System Inspection 631
Repair Instructions 632
Learning Control Initialization 632
A/T Fluid Level Check 632
A/T Fluid Change 633
Selector Lever Components 633
Select Lever Assembly Installation 634
Select Lever Knob Installation 634
Selector Lever Inspection 634
Select Cable Components 634
Select Cable Removal and Installation 635
Select Cable Adjustment 635
Transmission Range Sensor (Shift Switch) Inspection and Adjustment 636
Output Shaft Speed Sensor (VSS) Removal and Installation 636
Output Shaft Speed Sensor (VSS) Inspection 637
Input Shaft Speed Sensor Removal and Installation 637
Input Shaft Speed Sensor Inspection 637
Transmission Fluid Temperature Sensor Removal and Installation 638
Transmission Fluid Temperature Sensor Inspection 638
“3” Position Switch Inspection 639
Solenoid Valves (Shift Solenoid Valves and Timing Solenoid Valve) Removal and Installation 639
Solenoid Valves (Shift Solenoid Valves, and Timing Solenoid Valve) Inspection 640
Pressure Control Solenoid Valves (Pressure Control Solenoid and TCC Pressure Control Solenoid) Removal and Installation 642
Pressure Control Solenoid Valve Inspection 642
Transmission Control Module (TCM) Removal and Installation 643
A/T Relay Inspection 644
Differential Side Oil Seal Replacement 644
Shift Lock Solenoid Inspection 645
Shift Lock Solenoid Replacement 645
Key Interlock Cable Removal and Installation 646
A/T Fluid Cooler Hoses Replacement 647
Automatic Transaxle Unit Components 647
Automatic Transaxle Unit Dismounting and Remounting 648
Automatic Transaxle Assembly Components 650
Automatic Transaxle Unit Disassembly 652
Oil Pump Assembly Components 663
Oil Pump Assembly Disassembly and Reassembly 664
Oil Pump Assembly Inspection 664
Direct Clutch Assembly Components 666
Direct Clutch Assembly Preliminary Check 666
Direct Clutch Assembly Disassembly and Reassembly 667
Direct Clutch Assembly Inspection 669
Forward and Reverse Clutch Assembly Components 670
Forward and Reverse Clutch Assembly Preliminary Check 670
Forward and Reverse Clutch Assembly Disassembly and Reassembly 671
Forward and Reverse Clutch Assembly Inspection 674
2nd Brake Piston Assembly Components 675
2nd Brake Piston Assembly Disassembly and Reassembly 675
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Components 676
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Disassembly and Reassembly 677
Transaxle Rear Cover (O/D and 2nd Coast Brake Piston) Assembly Inspection 678
Countershaft Assembly Components 679
Countershaft Assembly Disassembly and Reassembly 679
Valve Body Assembly Components 680
Valve Body Assembly Disassembly and Reassembly 681
Differential Assembly Components 682
Differential Assembly Disassembly and Reassembly 683
Differential Assembly Inspection 684
Torque Converter Housing Disassembly and Reassembly 685
Transaxle Case Disassembly and Reassembly 687
Automatic Transaxle Unit Inspection and Adjustment 688
Automatic Transaxle Unit Assembly 690
Specifications 706
Tightening Torque Specifications 706
Special Tools and Equipment 707
Recommended Service Material 707
Special Tool 707
Manual Transmission 710
General Description 710
Manual Transaxle Construction and Servicing 710
Diagnostic Information and Procedures 712
Manual Transaxle Symptom Diagnosis 712
Repair Instructions 712
Manual Transaxle Oil Change 712
Differential Side Oil Seal Replacement 713
Gear Shift Control Lever and Cable Components 714
Gear Shift Control Lever and Cable Removal and Installation 715
Gear Select Control Cable Adjustment 715
Vehicle Speed Sensor (VSS) Removal and Installation 716
Back Up Lamp Switch Removal and Installation 716
Back Up Lamp Switch Inspection 717
Manual Transaxle Unit Components 717
Manual Transaxle Unit Dismounting and Remounting 718
Gear Shift and Select Shaft Assembly Components 720
Gear Shift and Select Shaft Assembly Removal and Installation 720
Gear Shift and Select Shaft Disassembly and Assembly 721
Manual Transaxle Assembly Components 722
Fifth Gear Disassembly and Assembly 723
Manual Transaxle Assembly Disassembly and Reassembly 726
Transaxle Right Case Disassembly and Assembly 731
Transaxle Left Case Disassembly and Assembly 732
Input Shaft and Countershaft Components 733
Input Shaft Assembly Disassembly and Reassembly 734
Countershaft Assembly Disassembly and Reassembly 736
Synchronizer Parts Inspection 739
Gear Shift Shaft Components 739
5th and Reverse Gear Shift Shafts Disassembly and Assembly 740
Gear Shift Shaft and Fork Inspection 740
Differential Components 741
Differential Disassembly and Assembly 741
Specifications 743
Tightening Torque Specifications 743
Special Tools and Equipment 744
Recommended Service Material 744
Special Tool 744
Clutch 747
General Description 747
Clutch Construction 747
Diagnostic Information and Procedures 748
Clutch System Symptom Diagnosis 748
Repair Instructions 749
Clutch Pedal Inspection 749
Clutch Fluid Level Inspection 750
Air Bleeding of Clutch System 750
Clutch Fluid Pipe and Hose Components 751
Clutch Fluid Pipe Removal and Installation 751
Clutch Fluid Pipe Inspection 752
Clutch Master Cylinder Removal and Installation 752
Clutch Operating Cylinder Removal and Installation 752
Clutch Pedal and Clutch Pedal Bracket Components 753
Clutch Cover, Clutch Disc and Flywheel Components 754
Clutch Cover, Clutch Disc and Flywheel Removal and Installation 754
Clutch Cover, Clutch Disc and Flywheel Inspection 756
Clutch Release System Removal and Installation 756
Clutch Release System Inspection 758
Specifications 758
Tightening Torque Specifications 758
Special Tools and Equipment 759
Recommended Service Material 759
Special Tool 759
Steering 761
Precautions 763
Precautions 763
Precautions on Steering 763
Steering General Diagnosis 764
Precautions 764
Precautions for Steering Diagnosis 764
Diagnostic Information and Procedures 765
Steering Symptom Diagnosis 765
Steering Wheel and Column 766
Precautions 766
Service Precautions of Steering Wheel and Column 766
Diagnostic Information and Procedures 766
Checking Steering Column for Accident Damage 766
Repair Instructions 767
Steering Wheel and Column Construction 767
Steering Wheel Removal and Installation 767
Contact Coil Cable Assembly Removal and Installation 768
Centering Contact Coil Cable Assembly 769
Contact Coil Cable Assembly Inspection 770
Steering Column Removal and Installation 770
Steering Column Inspection 772
Steering Lower Shaft Removal and Installation 772
Specifications 773
Tightening Torque Specifications 773
Special Tools and Equipment 773
Special Tool 773
Power Assisted Steering System 774
Precautions 774
Steering System Note 774
Precautions in Diagnosing Troubles 774
General Description 774
P/S System Description 774
EPS Diagnosis General Description 775
On-Board Diagnostic System Description 775
Schematic and Routing Diagram 776
EPS System Wiring Circuit Diagram 776
Diagnostic Information and Procedures 777
EPS System Check 777
“EPS” Warning Lamp Check 778
DTC Check 779
DTC Clearance 779
DTC Table 779
Scan Tool Data 781
P/S System Symptom Diagnosis 782
Serial Data Link Circuit Check 782
“EPS” Warning Lamp Does Not Come ON at Ignition Switch ON but Engine Stop 784
“EPS” Warning Lamp Come ON Steady and Engine Start 786
DTC C1113 / C1117 /C1118: Torque Sensor Circuit Failure 787
DTC C1114: Torque Sensor 5 V Power Supply Circuit Failure 788
DTC C1119: Torque Sensor 12 V Power Supply Circuit Failure 790
DTC C1121 / C1123 / C1124: VSS Circuit Failure 792
DTC C1122: Engine Speed Signal Circuit Failure 794
DTC C1141 / C1142 / C1143 / C1145: Motor Circuit Failure 795
DTC C1153: P/S Control Module Power Supply Circuit Failure 796
DTC C1155: P/S Control Module Failure 798
Inspection of P/S Control Module and Its Circuits 798
Steering Wheel Play Check 801
Steering Force Check 801
Repair Instructions 802
Steering Gear Case Assembly Components 802
Tie-Rod End Boot On-Vehicle Inspection 803
Tie-Rod End Removal and Installation 803
Tie-Rod End Inspection 804
Steering Shaft Joint On-Vehicle Inspection 804
Steering Gear Case Assembly Removal and Installation 804
Steering Rack Boot Inspection 806
Tie-Rod / Rack Boot Removal and Installation 806
Steering Rack Plunger Removal and Installation 808
Steering Rack Plunger Inspection 808
P/S Control Module Removal and Installation 808
Torque Sensor Inspection 809
Motor Assembly Inspection 809
Specifications 810
Tightening Torque Specifications 810
Special Tools and Equipment 811
Recommended Service Material 811
Special Tool 811
HVAC 813
Precautions 814
Precautions 814
Precautions on HVAC 814
Heater and Ventilation 815
General Description 815
Heater and Ventilation Construction 815
Schematic and Routing Diagram 816
Heater and Ventilation Wiring Circuit Diagram 816
Diagnostic Information and Procedures 817
Heater and Ventilation Symptom Diagnosis 817
Repair Instructions 818
HVAC Unit Components 818
HVAC Unit Removal and Installation 819
Blower Motor Removal and Installation 819
Blower Motor Inspection 819
Blower Motor Resistor Removal and Installation 820
Blower Motor Resistor Inspection 820
HVAC Control Unit Components 821
HVAC Control Unit Removal and Installation 821
Blower Speed Selector Inspection 822
Air Intake Switch Inspection 823
Air Intake Control Actuator Removal and Installation 823
Air Intake Control Actuator Inspection 823
Center Ventilation Louver Removal and Installation 824
Side Ventilation Louver Removal and Installation 824
Air Filter Removal and Installation 825
Air Filter Cleaning 825
Air Conditioning System 826
Precautions 826
A/C System Caution 826
Precautions on Servicing A/C System 826
General Description 828
Refrigerant Type Construction 828
Sub-Cool A/C System Description 828
Schematic and Routing Diagram 830
Major Components of A/C System 830
A/C System Wiring Diagram 831
Diagnostic Information and Procedures 832
A/C System Symptom Diagnosis 832
Abnormal Noise Symptom Diagnosis of A/C System 834
A/C System Performance Inspection 835
A/C System Inspection at ECM 840
Repair Instructions 842
Operation Procedure for Refrigerant Charge 842
Condenser Assembly On-Vehicle Inspection 847
Condenser Assembly Removal and Installation 847
Desiccant Removal and Installation 848
HVAC Unit Components 849
HVAC Unit Removal and Installation 850
Evaporator Inspection 850
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation 850
Evaporator Thermistor (Evaporator Temperature Sensor) Inspection 851
Expansion Valve Removal and Installation 851
Expansion Valve Inspection 852
A/C Refrigerant Pressure Sensor and Its Circuit Inspection 852
A/C Refrigerant Pressure Sensor Removal and Installation 852
A/C Switch Inspection 852
Compressor Relay Inspection 853
Compressor Drive Belt Inspection and Adjustment 853
Compressor Drive Belt Removal and Installation 854
Compressor Assembly Removal and Installation 854
Compressor Assembly Components 855
Magnet Clutch Inspection 855
Magnet Clutch Removal and Installation 855
Relief Valve Inspection 857
Relief Valve Removal and Installation 857
Specifications 858
Tightening Torque Specifications 858
Special Tools and Equipment 859
Recommended Service Material 859
Special Tool 859
Restraint 861
Precautions 863
Precautions 863
Precautions on Restraint 863
Seat Belts 864
Precautions 864
Precautions on Service and Diagnosis of Seat Belt 864
General Description 864
Seat Belt Construction 864
Diagnostic Information and Procedures 865
Repair and Inspection Required after Accident 865
Repair Instructions 866
Front Seat Belt Components 866
Front Seat Belt Removal and Installation 866
Front Seat Belt Inspection 867
Rear Seat Belt Components 869
Rear Seat Belt Removal and Installation 870
Rear Seat Belt Inspection 870
Specifications 870
Tightening Torque Specifications 870
Air Bag System 871
Precautions 871
Precautions on Service and Diagnosis of Air Bag System 871
Precautions on Handling and Storage of Air Bag System Components 871
Precautions on Disposal of Air Bag and Seat Belt Pretensioner 875
General Description 875
Air Bag System Construction 875
Air Bag System Input / Output Table 876
Schematic and Routing Diagram 877
Air Bag System Wiring Circuit Diagram 877
Component Location 879
Air Bag System Components, Wiring and Connectors Location 879
Diagnostic Information and Procedures 880
Air Bag Diagnostic System Check 880
Air Bag Diagnostic System Check Flow 880
DTC Table 881
DTC Check 882
DTC Clearance 882
Scan Tool Data 883
“AIR BAG” Warning Lamp Comes ON Steady 883
“AIR BAG” Warning Lamp Does Not Come ON 885
“AIR BAG” Warning Lamp Flashes 887
DTC B1013: SDM fault 888
DTC B1014: “AIR BAG” Warning Lamp Circuit Failure 888
DTC B1016: Power Source Voltage High 889
DTC B1017: Power Source Voltage Low 891
DTC B1021: Front Air Bag Module Deployed 893
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed 893
DTC B1026: Pretensioner Activated 894
DTC B1027: Reusable Number Exceeded 895
DTC B1031: Driver Air Bag Initiator Circuit Resistance High 895
DTC B1032: Driver Air Bag Initiator Circuit Resistance Low 900
DTC B1033: Driver Air Bag Initiator Circuit Short to Ground 905
DTC B1034: Driver Air Bag Initiator Circuit Short to Power Circuit 910
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High 915
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low 919
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground 923
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circuit 927
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance High 931
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circuit Resistance Low 934
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground 937
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power Circuit 939
DTC B1061 / B1065: Driver / Passenger Side-Air Bag Initiator Circuit Resistance High 941
DTC B1062 / B1066: Driver / Passenger Side-Air Bag Initiator Circuit Resistance Low 945
DTC B1063 / B1067: Driver / Passenger Side-Air Bag Initiator Circuit Short to Ground 949
DTC B1064 / B1068: Driver / Passenger Side-Air Bag Initiator Circuit Short to Power Circuit 952
DTC B1071: Forward-Sensor Performance Problem 955
DTC B1072: Forward-Sensor Communication Error 955
DTC B1073: Forward-Sensor Circuit Short to Ground 955
DTC B1074: Forward-Sensor Circuit Short to Power Circuit or Open 957
DTC B1081 / B1091: Driver / Passenger Side-Sensor Performance Problem 959
DTC B1082 / B1092: Driver / Passenger Side-Sensor Communication Error 959
DTC B1083 / B1093: Driver / Passenger Side-Sensor Circuit Short to Ground 959
DTC B1084 / B1094: Driver / Passenger Side-Sensor Circuit Short to Power Circuit or Open 961
DTC B1085 / B1095: Wrong Side-Sensor (Driver Side / Passenger) ID 963
DTC B1361 / B1365: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance High 963
DTC B1362 / B1366: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Resistance Low 965
DTC B1363 / B1367: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Ground 967
DTC B1364 / B1368: Driver / Passenger Side Curtain-Air Bag Initiator Circuit Short to Power Circuit 969
Inspection of Intermittent and Poor Connections 971
Repair and Inspection Required after Accident 972
Repair Instructions 975
Disabling Air Bag System 975
Enabling Air Bag System 975
SDM Removal and Installation 976
SDM Inspection 977
Driver Air Bag (Inflator) Module Removal and Installation 977
Driver Air Bag (Inflator) Module Inspection 978
Passenger Air Bag (Inflator) Module Removal and Installation 979
Passenger Air Bag (Inflator) Module Inspection 980
Side-Air Bag (Inflator) Module Removal and Installation 981
Side-Air Bag (Inflator) Inspection 982
Side Curtain-Air Bag (Inflator) Module Removal and Installation 983
Side Curtain-Air Bag (Inflator) Module Inspection 984
Forward-Sensor Removal and Installation 984
Forward-Sensor Inspection 985
Side-Sensor Removal and Installation 985
Side-Sensor Inspection 986
Passenger Air Bag (Inflator) Module Repair Harness Installation 987
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal 988
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal 998
Specifications 999
Tightening Torque Specifications 999
Special Tools and Equipment 999
Use of Special Tools 999
Recommended Service Material1000
Special Tool1001
Body, Cab and Accessories1003
Precautions1007
Precautions1007
Precautions on Body, Cab and Accessories1007
Precautions for Body Service1007
Fastener Caution for Body Service1007
Wiring Systems1008
Precautions1008
Cautions in Body Electrical System Servicing1008
Precautions for Wiring System1008
General Description1009
Applicable model1009
Abbreviations1009
Wire / Connector Color Symbols1010
Symbols and Marks1010
How to Read Connector Layout Diagram1012
How to Read Connector Codes and Terminal Nos1013
How to Read Ground Point1015
How to Read Power Supply Diagram1016
How to Read System Circuit Diagram1016
Connector Layout Diagram1018
Connector Layout Diagram1018
Engine Compartment1018
Instrument Panel1020
Door, Roof1022
Floor1023
Rear1025
Ground Point1026
Ground (earth) Point1026
Power Supply Diagram1027
Power Supply Diagram1027
Fuses and the Protected Parts1028
Fuses in Main Fuse Box1029
Individual Circuit Fuse Box No 11029
Individual Circuit Fuse Box No 2 (In J/B)1030
Junction Block (J/B) Connector / Fuse Layout1032
Junction Block Inner Circuit (Overview)1034
Junction Block Inner Circuit (Detail)1035
System Circuit Diagram1040
System Circuit Diagram1040
A-1 Cranking System Circuit Diagram1041
A-2 Charging System Circuit Diagram1042
A-3 Ignition System Circuit Diagram1043
A-4 Cooling System Circuit Diagram1044
A-5 Engine and A/C Control System Circuit Diagram1045
A-6 A/T Control System Circuit Diagram1050
A-7 Immobilizer System Circuit Diagram1052
A-8 Body Control System Circuit Diagram1053
B-1 Windshield Wiper and Washer Circuit Diagram1057
B-2 Rear Wiper and Washer Circuit Diagram1058
B-3 Rear Defogger Circuit Diagram1059
B-4 Power Window Circuit Diagram1060
B-5 Power Door Lock Circuit Diagram1062
B-6 Power Mirror Circuit Diagram1064
B-7 Horn Circuit Diagram1065
C-1 Combination Meter Circuit Diagram (Meter)1066
C-2 Combination Meter Circuit Diagram (Indicator)1067
C-3 Combination Meter Circuit Diagram (Warning Light)1068
D-1 Headlight System Circuit Diagram1070
D-2 Position, Tail and Licence Plate Light System Circuit Diagram1071
D-3 Front Fog Light System Circuit Diagram1072
D-4 Illumination Light System Circuit Diagram1073
D-5 Interior Light System Circuit Diagram1074
D-6 Turn Signal and Hazard Warning Light System Circuit Diagram1075
D-7 Brake Light System Circuit Diagram1077
D-8 Back-Up Light System Circuit Diagram1078
E-1 Heater System Circuit Diagram1079
F-1 Air-Bag System Circuit Diagram1081
F-2 Anti-Lock Brake System Circuit Diagram1083
F-3 Power Steering System Circuit Diagram1085
G-1 Audio System Circuit Diagram1087
G-2 Multi Information Display / Accessory Socket System Circuit Diagram1088
List of Connectors1089
List of Connectors1089
C Connector1089
E Connector1090
G Connector1091
J Connector1093
K Connector1094
L Connector1094
O Connector1095
R Connector1095
Lighting Systems1096
Component Location1096
Lighting System Location1096
Interior Light System Location1097
Diagnostic Information and Procedures1097
Headlight Symptom Diagnosis1097
Turn Signal and Hazard Warning Light Symptom Diagnosis1098
Clearance, Tail and License Plate Light Symptom Diagnosis1098
Back-Up Light Symptom Diagnosis1099
Stop (Brake) Lamp Symptom Diagnosis1099
Front Fog Light Symptom Diagnosis (If Equipped)1099
Interior Light Symptom Diagnosis1100
Repair Instructions1100
Headlight Housing Removal and Installation1100
Headlight Bulb Replacement1101
Headlight Aiming Adjustment with Screen1101
Headlight Switch (in Lighting Switch) Removal and Installation1102
Headlight Switch (in Lighting Switch) Inspection1103
Hazard Warning Switch Removal and Installation1103
Hazard Warning Switch Inspection1103
Stop (Brake) Lamp Switch Inspection1104
Turn Signal Light Switch (in Lighting Switch) Removal and Installation1104
Turn Signal Light Switch (in Lighting Switch) Inspection1104
Turn Signal and Hazard Warning Relay Removal and Installation1104
Turn Signal and Hazard Warning Relay Inspection1104
License Lamp Assembly Removal and Installation1105
Front Fog Light Assembly Removal and Installation1105
Front Fog Light Bulb Replacement1106
Front Fog Light Switch Inspection1106
Front Fog Light Relay Inspection1106
Front Fog Light Aiming Adjustment with Screen1107
Instrumentation / Driver Info / Horn1108
General Description1108
CAN Communication Data of Combination Meter1108
Schematic and Routing Diagram1109
Combination Meter Circuit Diagram1109
Component Location1110
Audio System Component Location1110
Diagnostic Information and Procedures1111
Speedometer and VSS Symptom Diagnosis1111
Tacho meter Symptom Diagnosis1111
Engine Coolant Temperature (ECT) Meter Symptom Diagnosis1111
Fuel Meter Symptom Diagnosis1111
Low Fuel Warning Light Symptom Diagnosis1112
Oil Pressure Warning Light Symptom Diagnosis1112
Brake and Parking Brake Warning Light Symptom Diagnosis1113
Seat Belt Reminder Light Symptom Diagnosis (If Equipped)1113
A/T Shift Position Indicator (A/T Vehicle Only) Symptom Diagnosis1113
Charge Warning Light Symptom Diagnosis1114
Main Beam (High Beam) Indicator Symptom Diagnosis1114
Warning Buzzer Circuit Symptom Diagnosis1114
Cigarette Lighter Symptom Diagnosis (If Equipped)1114
Horn Symptom Diagnosis1115
Information Display Symptom Diagnosis (If Equipped)1115
Audio System Symptom Diagnosis (If Equipped)1116
Remote Audio Control Switch (If Equipped) Symptom Diagnosis1117
Repair Instructions1117
Ignition Switch Removal and Installation1117
Ignition Switch Inspection1118
Combination Meter Removal and Installation1118
Fuel Level Sensor Removal and Installation1118
Fuel Level Sensor Inspection1118
Oil Pressure Switch Removal and Installation1119
Oil Pressure Switch Inspection1119
VSS Removal and Installation1119
VSS Inspection1119
Engine Coolant Temperature (ECT) Sensor Inspection1119
Brake Fluid Level Switch Inspection1119
Parking Brake Switch Inspection1120
Door Switch (Front / Rear Door) Inspection1120
Rear End Door Switch Inspection1120
Outside Air Temperature Sensor Removal and Installation1120
Outside Air Temperature Sensor Inspection1121
Instrument Panel Removal and Installation1121
Information Display Removal and Installation1122
Radio Assembly Removal and Installation1123
Front Speaker Removal and Installation1123
Rear Speaker Removal and Installation1123
Horn Removal and Installation1123
Horn Inspection1124
Horn Relay Inspection1124
Antenna Amplifier Removal and Installation1124
Remote Audio Control Switch Inspection1124
Specifications1125
Tightening Torque Specifications1125
Wipers / Washers1126
Diagnostic Information and Procedures1126
Front Wiper and Washer Symptom Diagnosis1126
Rear Wiper and Washer (If Equipped) Symptom Diagnosis1126
Repair Instructions1127
Wipers and Washers Components1127
Washer Tank and Washer Pump Removal and Installation1128
Washer Pump Inspection1128
Windshield Wiper Removal and Installation1129
Windshield Wiper Motor Inspection1129
Rear Wiper (If Equipped) Removal and Installation1130
Rear Wiper Motor (If Equipped) Inspection1131
Windshield Wiper and Washer Switch Removal and Installation1132
Windshield Wiper and Washer Switch Inspection1132
Rear Wiper and Washer Switch Removal and Installation1133
Rear Wiper and Washer Switch Inspection1134
Rear Wiper Relay Removal and Installation1134
Rear Wiper Relay Inspection1134
Specifications1134
Tightening Torque Specifications1134
Glass / Windows / Mirrors1135
General Description1135
Rear End Door Window Defogger System Description1135
Windshield Construction1135
Diagnostic Information and Procedures1136
Rear End door Window Defogger Symptom Diagnosis1136
Power Window Control System Symptom Diagnosis1136
Power Door Mirror Control System (If Equipped) Symptom Diagnosis1137
Repair Instructions1137
Windshield Removal and Installation1137
Front Door Window Components1140
Front Door Glass Removal and Installation1141
Front Door Window Regulator Removal and Installation1142
Front Door Window Regulator Inspection1142
Rear Door Window Components1143
Rear Door Glass Removal and Installation1143
Rear Door Window Regulator Removal and Installation1144
Rear Door Window Regulator Inspection1145
Rear End Door Window Components1145
Rear End Door Glass Removal and Installation1145
Rear End Door Window Defogger Switch Inspection1146
Rear End Door Window Defogger Relay Inspection1146
Rear End Door Window Defogger Wire Inspection1147
Rear End Door Window Defogger Wire Repair1147
Power Window Main Switch Inspection1148
Power Window Sub Switch Inspection1149
Door Mirror Components1149
Door Mirror Removal and Installation1150
Power Door Mirror Switch Inspection1150
Power Door Mirror Actuator Inspection1150
Special Tools and Equipment1150
Recommended Service Material1150
Security and Locks1151
General Description1151
Key Coding Construction1151
Rear End Door Opener System Description1151
Component Location1152
Power Door Lock and Keyless Entry System Component Location1152
Diagnostic Information and Procedures1153
Power Door Lock System Symptom Diagnosis1153
Power Door Lock System Operation Inspection1153
Keyless Entry System Symptom Diagnosis1154
Keyless Entry System Operation Inspection1154
Rear End Door Opener System Symptom Diagnosis1155
Rear End Door Opener System Operation Inspection1155
Repair Instructions1155
Front Door Lock Assembly Components1155
Front Door Lock Assembly Removal and Installation1156
Front Door Lock Assembly Inspection1157
Power Door Lock Switch Inspection1157
Door Key Cylinder Switch Inspection1158
Power Door Lock Actuator Inspection1158
Rear Door Lock Assembly Components1159
Rear Door Lock Assembly Removal and Installation1159
Rear Door Lock Assembly Inspection1159
Rear End Door Lock Assembly Components1160
Rear End Door Lock Assembly Removal and Installation1160
Rear End Door Lock Assembly Inspection1161
Rear End Door Opener Switch Inspection1161
Replacement of Transmitter Battery1161
Programming Transmitter Code1162
Keyless Entry Receiver Removal and Installation1162
Keyless Entry Receiver and Its Circuit Inspection1163
Specifications1164
Tightening Torque Specifications1164
Special Tools and Equipment1164
Recommended Service Material1164
Seats1165
Repair Instructions1165
Front Seat Components1165
Front Seat Removal and Installation1165
Rear Seat Components1166
Rear Seat Removal and Installation1166
Specifications1166
Tightening Torque Specifications1166
Interior Trim1167
Repair Instructions1167
Floor Carpet Removal and Installation1167
Head Lining Removal and Installation1167
Console Box Components1168
Roof Molding Components1169
Splash Guard (If Equipped) Components1169
Specifications1170
Tightening Torque Specifications1170
Hood / Fenders / Doors1171
Repair Instructions1171
Hood Removal and Installation1171
Hood Inspection and Adjustment1171
Front Fender Components1172
Front Fender Removal and Installation1172
Front Door Assembly Components1173
Front Door Assembly Removal and Installation1173
Rear Door Assembly Components1174
Rear Door Assembly Removal and Installation1175
Rear End Door Assembly Components1175
Rear End Door Assembly Removal and Installation1175
Specifications1177
Tightening Torque Specifications1177
Special Tools and Equipment1177
Recommended Service Material1177
Body Structure1178
Repair Instructions1178
Front Bumper and Rear Bumper Components1178
Cowl Top Components1179
Specifications1180
Body Dimensions1180
Panel Clearance1187
Paint / Coatings1188
General Description1188
Anti-Corrosion Treatment Construction1188
Plastic Parts Finishing1188
Component Location1189
Sealant Application Areas1189
Under Coating Application Areas1194
Anti-Corrosion Compound Application Area1196
Exterior Trim1197
Repair Instructions1197
Roof Molding Components1197
Splash Guard (If Equipped) Components1198
Control systems1199
Precautions1200
Precautions1200
Precautions for Control Systems1200
Body Electrical Control System1201
Precautions1201
Precautions in Diagnosing Trouble1201
General Description1201
BCM General Description1201
CAN Communication System Description1202
Schematic and Routing Diagram1203
Body Electrical Control System Wiring Circuit Diagram1203
Connector Layout Diagram of BCM and Junction Block Assembly1206
Component Location1207
BCM and Related System Component Location1207
Diagnostic Information and Procedures1208
BCM Self-Diagnosis Function1208
Body Electrical Control System Check1209
Scan Tool Data1211
DTC Table1213
DTC Check1213
DTC Clearance1215
BCM Power Circuit and Ground Circuit Check1215
DTC B1133 (DTC No1133): Battery Voltage Too High1217
DTC B1141 / DTC B1142 / DTC B1143 (No1141 / No 1142/ No 1143) Outside Air Temperature (Ambient Temp) Sensor Circuit Malfunction1218
DTC B1150 (No 1150): Air Bag Communication Circuit Malfunction1220
DTC B1157 (No1157) Air Bag Deployment Signal Input1222
DTC B1170 (No 1170): EEPROM access error1222
DTC U1001 (No 1001): High Speed CAN Communication (Transmission Error)1223
DTC U1073 (No 1073): Control Module Communication Bus Off1225
DTC U1100 (No1100): Lost communication with ECM1227
DTC U1101 (No1101): Lost communication with TCM1229
Inspection of BCM and its Circuits1230
Repair Instructions1239
BCM (Included in Junction Block Assembly) Removal and Installation1239
Outside Air Temperature Sensor Removal and Installation1239
Outside Air Temperature Sensor Inspection1239
Special Tools and Equipment1240
Special Tool1240
Immobilizer Control System1241
Precautions1241
Precautions in Diagnosing Troubles1241
Precaution in Replacing ECM1241
Precautions in Handling Immobilizer Control System1241
General Description1242
Immobilizer Control System Introduction1242
Immobilizer Control System Components Location1242
On-Board Diagnostic System Description (Self- diagnosis Function)1243
Schematic and Routing Diagram1243
Immobilizer Control System Wiring Circuit Diagram1243
Diagnostic Information and Procedures1245
Immobilizer Control System Check1245
Diagnostic Trouble Code (DTC) Check1245
Diagnostic Trouble Code (DTC) Clearance1245
Diagnostic Trouble Code (DTC) Table1246
Scan Tool Data1246
DTC P1614 Transponder Response Error1247
DTC P1621 Immobilizer Communication Line Error1248
DTC P1622 EEPROM Error1250
DTC P1623 Unregistered Transponder1250
DTC P1625 Immobilizer Antenna Error1251
Inspection of Immobilizer Control Module and Its Circuit1252
Repair Instructions1254
Immobilizer Control Module Removal and Installation1254
Registration of the Ignition Key1254
Procedure after ECM Replacement1254
Special Tools and Equipment1254
Special Tool1254
COPYRIGHT1255
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