Mazda6 Workshop Manual FOREWORD This manual contains on-vehicle service and diagnosis for the Mazda6. For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference. All the contents of this manual, including drawings and specifications, are the latest available at the time of printing.
VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. JMZ GG12820# JMZ GG14320# JMZ GG14820# JMZ GG12F20# JMZ GG12F50# JMZ GG14F20# JMZ GG14F50# 100001 100001 100001 100001 100001 100001 100001 European (L.H.D.) specs. JMZ GG1232✻ ✻# 100001 JMZ GG1282✻ ✻# 100001 JMZ GG1432✻ ✻# 100001 JMZ GG1482✻ ✻# 100001 JMZ GG12F2✻ ✻# 100001 JMZ GG12F5✻ ✻# 100001 JMZ GG14F2✻ ✻# 100001 JMZ GG14F5✻ ✻# 100001 GCC specs.
WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations.
GENERAL INFORMATION GI G I HOW TO USE THIS MANUAL ..............................GI-2 RANGE OF TOPICS ...........................................GI-2 SERVICE PROCEDURE ....................................GI-2 SYMBOLS...........................................................GI-4 ADVISORY MESSAGES ....................................GI-4 TROUBLESHOOTING PROCEDURE ................GI-5 UNITS ..................................................................GI-11 UNITS ........................................
HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS A6E201000001W01 • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: Removal/Installation Disassembly/Assembly Replacement Inspection Adjustment • Simple operations which can be performed easily just by looking at the vehicle (i.e.
HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2. Expendable parts, tightening torques and symbols for oil, grease, and sealant are shown in the overview illustration.
HOW TO USE THIS MANUAL SYMBOLS A6E201000001W03 • There are eight symbols indicating oil, grease, fluids, sealant, and SST or equivalent use. These symbols show application points or use of these materials during service.
HOW TO USE THIS MANUAL TROUBLESHOOTING PROCEDURE Basic flow of troubleshooting A6E201000001W05 GI XME2010002 DTC troubleshooting flow (on-board diagnostic) • Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction. • The on-board diagnostic function is used during inspection.
HOW TO USE THIS MANUAL Procedures for Use Using the basic inspection (section K) • Perform the basic inspection procedure before symptom troubleshooting. • Perform each step in the order shown. • The reference column lists the location of the detailed procedure for each basic inspection.
HOW TO USE THIS MANUAL Using the DTC troubleshooting flow • DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC.
HOW TO USE THIS MANUAL Using the diagnosis index • The symptoms of the malfunctions are listed in the diagnostic index for symptom troubleshooting. • The exact malfunction symptoms can be selected by following the index.
HOW TO USE THIS MANUAL Using the quick diagnosis chart • The chart lists the relation between the symptom and the cause of the malfunction. • The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It also specifies the area of the common cause when multiple malfunction symptoms occur.
HOW TO USE THIS MANUAL Using the symptom troubleshooting • Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to take for each trouble symptom.
UNITS UNITS GI UNITS Electrical current Electric power Electric resistance Electric voltage Length Negative pressure Positive pressure Torque Volume Weight A6E201200002W01 A (ampere) W (watt) Ω (ohm) V (volt) mm (millimeter) in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) N·m (Newton meter) kgf·m (kilogram force meter) kgf·cm (kilogram force centimeter) ft·lbf (foot pound
FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PROTECTION OF VEHICLE • Always be sure to cover fenders, seats and floor areas before starting work. End Of Sie PREPARATION OF TOOLS AND MEASURING EQUIPMENT • Be sure that all necessary tools and measuring equipment are available before starting any work. A6E201400004W01 X3U000WAG A6E201400004W02 X3U000WAH End Of Sie SPECIAL SERVICE TOOLS • Use special service tools or equivalent when they are required.
FUNDAMENTAL PROCEDURES 5. If no dye leakage is found, allow the engine to run for another 30 minutes or drive the vehicle then reinspect. 6. Find where the oil is leaking from, then make necessary repairs. Note • To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the fluorescent dye instruction manual. Not Using UV Light (Black Light) 1. Gather some of the leaking oil using an absorbent white tissue. 2.
FUNDAMENTAL PROCEDURES INSPECTION DURING REMOVAL, DISASSEMBLY • When removed, each part should be carefully inspected for malfunction, deformation, damage, and other problems. A6E201400004W08 X3U000WAM End Of Sie ARRANGEMENT OF PARTS • All disassembled parts should be carefully arranged for reassembly. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
FUNDAMENTAL PROCEDURES • If removed, these parts should be replaced with new ones: Oil seals Gaskets O-rings Lockwashers Cotter pins Nylon nuts • Depending on location: Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts.
FUNDAMENTAL PROCEDURES HOSE CLAMPS • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. A6E201400004W14 WGIWXX0035J End Of Sie TORQUE FORMULAS • When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque using the following formulas.
FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM DYNAMOMETER A6E201400004W17 • When inspecting and servicing the power train on the dynamometer or speed meter tester, pay attention to the following: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Make sure the vehicle is in a facility with an exhaust gas ventilation system. Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be below 70 degrees.
ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL PARTS Battery cable • Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. A6E201700006W01 WGIWXX0007E Wiring Harness • To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver. X3U000WBU End Of Sie CONNECTORS Data link connector • Insert the probe into the terminal when connecting a jumper wire to the data link connector.
ELECTRICAL SYSTEM • Connectors can be disconnected by pressing or pulling the lock lever as shown. GI WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked. X3U000WB1 Inspection • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side. X3U000WB2 • Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side.
ELECTRICAL SYSTEM Terminals Inspection • Pull lightly on individual wires to verify that they are secured in the terminal. X3U000WB4 Replacement • Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. • Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab pressed down, pull the terminal out from the connector.
ELECTRICAL SYSTEM Fuse Replacement • When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit probably has a short and the wiring should be inspected. • Be sure the negative battery terminal is disconnected before replacing a main fuse. GI YMU000WA1 • When replacing a pullout fuse, use the fuse puller. YMU000WAK Direction of View for Connector Part-side connector Direction of view is from the terminal side.
ELECTRICAL SYSTEM Vehicle-harness-side connector Direction of view is from the harness side. * : Part names are shown only when there are multiple connector drawings. WGIWXX0101E Other Because vehicle-harness-side connectors, such as the DLC 2, have to be viewed from the terminal side, the direction of view is from the terminal side. WGIWXX0102E End Of Sie ELECTRICAL TROUBLESHOOTING TOOLS Jumper wire • A jumper wire is used to create a temporary circuit.
ELECTRICAL SYSTEM Voltmeter • The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage will be measured and the negative (-) probe (black lead wire) to a body ground. GI X3U000WBC Ohmmeter • The ohmmeter is used to measure the resistance between two points in a circuit and to inspect for continuity and short circuits.
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS), SAFETY STANDS (RIGID RACK) POSITIONS JACKING POSITIONS ,VEHICLE LIFT (2 SUPPORTS), SAFETY STANDS (RIGID RACK) POSITIONS JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS Jacking Positions A6E202200019W01 Warning • Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking points and block the wheels.
JACKING POSITIONS ,VEHICLE LIFT (2 SUPPORTS), SAFETY STANDS (RIGID Jacking positions, vehicle lift (2 supports) and safety stand (rigid rack) positions view GI A6E2021W001 End Of Sie GI25
TOWING TOWING TOWING A6E202400009W01 • Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed. • A towed vehicle should have its front wheels off the ground. If excessive damage or other conditions prevent this, use wheel dollies. • When towing with the rear wheels on the ground, release the parking brake. Caution • Do not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the transaxle.
TOWING FRONT 1. Remove the towing eyelet and the lug wrench from the trunk. 2. Wrap a screwdriver or similar tool with a soft cloth to prevent damage to the painted bumper and open the cap located on the front bumper, below the left headlight. Caution • The cap cannot be completely removed. Do not use excessive force as it may damage the cap or scratch the painted bumper surface. 3. Securely install the towing eyelet using the lug wrench. 4. Hook the towing rope to the towing eyelet.
IDENTIFICATION NUMBER LOCATIONS IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER(VIN) A6E202600010W01 A6E2026W004 End Of Sie ENGINE IDENTIFICATION NUMBER A6E202600010W02 A6E2026W001 End Of Sie GI28
NEW STANDARDS NEW STANDARDS GI NEW STANDARDS A6E202800020W01 • Following is a comparison of the previous standard and the new standard.
NEW STANDARDS New Standard Abbreviation OC O2S PNP PSP PCM PAIR AIR SAPV SFI Name Output Speed Sensor Oxidation Catalytic Converter Oxygen Sensor Park/Neutral Position PCM Control Relay Power Steering Pressure Powertrain Control Module Pressure Control Solenoid Name Vehicle Speed Sensor 1 Catalytic Converter Oxygen Sensor Park/Neutral Range Main Relay Power Steering Pressure Engine Control Unit Line Pressure Solenoid Valve Pulsed Secondary Air Injection Secondary Air Injection System Pump Sp
ABBREVIATIONS ABBREVIATIONS GI ABBREVIATIONS A/C ABS ACC ALR ATF ATX CAN CM DIS DSC ELR ESA EX GPS HI IAC IG IN INT KOEO KOER LCD LED LF LH L.H.D.
PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION A6E203200012W01 PRE-DELIVERY INSPECTION TABLE EXTERIOR • INSPECT and ADJUST, if necessary, the following items to specification: ❏Glass, exterior bright metal and paint for damage ❏All weatherstrips for damage or detachment ❏Door operation and alignment including side door and back door ❏Wheel lug nuts ❏Tire pressures ❏Headlight aiming ❏Headlight cleaner and fluid level (if equipped) ❏Operation of bonnet release and lock ❏Operation o
SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE GI SCHEDULED MAINTENANCE TABLE A6E203400013W01 For Europe (L.H.D. U.K.) Chart symbols: I : Inspect and repair, clean, adjust, or replace if necessary. (Oil-permeated air cleaner elements cannot be cleaned using the air-blow method.) R : Replace T : Tighten L : Lubricate Remarks: • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly.
SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months 12 24 36 48 60 72 84 96 108 Maintenance Item ×1000 km 20 40 60 80 100 120 140 160 180 × 1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.
SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months 12 24 36 48 60 72 84 96 108 120 132 144 Maintenance Item ×1000 km 15 30 45 60 75 90 105 120 135 150 165 180 ×1000 miles 9 18 27 36 45 54 63 72 81 90 99 108 EMISSION CONTROL SYSTEM Evaporative system I I I E.G.R.
SCHEDULED MAINTENANCE Maintenance Item Maintenance Interval (Number of months or km (miles), whichever comes first) Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 ×1000 km 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 × 1000 miles 6.25 12.5 18.75 25 31.25 37.5 43.75 50 56.25 62.5 68.75 75 81.25 87.5 93.
SCHEDULED MAINTENANCE Scheduled Maintenance Service (Specific Work Required) For Europe (L.H.D. U.K.
SCHEDULED MAINTENANCE Maintenance Item Steering operation & linkages Power steering fluid & lines Power steering fluid Power steering system & hoses Steering & front suspension Steering operation & gear housing Steering linkages tie rod ends & arms Front & rear suspension ball joints Manual transmission/transaxle oil Automatic transaxle oil level Automatic transmission/transaxle fluid level Automatic transmission/transaxle fluid Front & rear differential oil Rear differential oil Transfer oil Upper arm sha
ENGINE B B LOCATION INDEX .................................................B-2 MECHANICAL LOCATION INDEX ...................... B-2 DRIVE BELT........................................................... B-3 DRIVE BELT INSPECTION ................................. B-3 DRIVE BELT REPLACEMENT ............................ B-3 DRIVE BELT AUTO TENSIONER INSPECTION .......................................................B-4 VALVE CLEARANCE............................................. B-4 VALVE CLEARANCE INSPECTION.
LOCATION INDEX LOCATION INDEX MECHANICAL LOCATION INDEX A6E220001002W01 A6E2200W300 .
DRIVE BELT End Of Sie DRIVE BELT DRIVE BELT INSPECTION A6E221015800W01 Note • Front and water pump drive belt deflection/tension inspection is not necessary because of the use of the front drive belt auto tensioner. Front Drive Belt 1. Verify that the drive belt auto tensioner indicator mark does not exceeds the limit. • If it exceeds the limit, replace the drive belt. (SeeB3 DRIVE BELT REPLACEMENT.) AME2210W001 End Of Sie DRIVE BELT REPLACEMENT 1. Remove the splash shield (RH). 2.
DRIVE BELT, VALVE CLEARANCE DRIVE BELT AUTO TENSIONER INSPECTION 1. Remove the drive belt. (See B3 DRIVE BELT REPLACEMENT.) 2. Verify that the drive belt auto tensioner moves smoothly in the operational direction. • Replace the drive belt auto tensioner if necessary. 3. Turn the drive belt auto tensioner pulley by hand and verify that it rotates smoothly. • Replace the drive belt auto tensioner if necessary. 4. Install the drive belt. (See B3 DRIVE BELT REPLACEMENT.
VALVE CLEARANCE 16. Install the splash shield (RH). 17. Install the tire (RH). End Of Sie VALVE CLEARANCE ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. A6E221212111W02 Disconnect the negative battery cable. Remove the tire (RH). Remove the splash shield (RH). Remove the spark plugs. (See G10 SPARK PLUG REMOVAL/INSTALLATION.) Remove the high-tension lead. Remove the oil control valve (OCV) connector. Remove the ventilation hose. Remove the cylinder head cover. Remove the drive belt.
VALVE CLEARANCE 16. Loosen the timing chain. (1) Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet. (2) Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain. (3) Placing the suitable bolt (M6 X 1.0 length 25mm35mm {0.99in1.37in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released. AME2212W005 17.
VALVE CLEARANCE New adjustment shim = Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in}) Standard [Engine cold] IN: 0.220.28 mm {0.00870.0110 in} (0.25± ±0.03 mm {0.0098± ±0.0011 in}) EX: 0.270.33 mm {0.01060.0130 in} (0.30± ±0.03 mm {0.0118± ±0.0011 in}) B 23. Install the camshaft with No.1 cylinder aligned with the TDC position. 24. Tighten the camshaft cap bolt using the following two steps. (1) Tighten to 5.09.0 N·m {51.
VALVE CLEARANCE 29. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown. 30. Tighten the exhaust camshaft sprocket lock bolt. Tightening torque: 6975 N·m {7.107.6 kgf·m, 50.955.3 ft·lbf} 31. Remove the SST from the camshaft. 32. Remove the SST from the block lower blind plug. 33. Rotate the crankshaft clockwise two turns until the TDC position. • If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 14. 34.
COMPRESSION PRESSURE COMPRESSION PRESSURE COMPRESSION INSPECTION A6E221402000W01 Warning • Hot engines and oil can cause severe burns. Be careful not to burn yourself during removal/ installation of each component. 1. Verify that the battery is fully charged. • Recharge it if necessary. (See G4 BATTERY INSPECTION.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 min. 4. Perform Fuel Line Safety Procedures.
COMPRESSION PRESSURE, TIMING CHAIN kPa {kgf/cm2, psi} [rpm] Item Standard Minimum Maximum difference between cylinders 11. 12. 13. 14. Engine type L3 1,430 {14.5819, 207.404} [290] 1,000 {10.197, 145.00} [290] 196.1 {1.999, 28.44} Disconnect the compression gauge. Install the spark plugs. (See G10 SPARK PLUG REMOVAL/INSTALLATION.) Connect the ignition coil connector. Install the fuel pump relay. (See F17 BEFORE REPAIR PROCEDURE.
TIMING CHAIN B . AME2215W001 1 2 3 4 5 6 7 Cylinder head cover (See B17 Cylinder Head Cover Installation Note) Crankshaft pulley lock bolt (See B12 Crankshaft Pulley Lock Bolt Removal Note) (See B16 Crankshaft Pulley Lock Bolt Installation Note) Crankshaft pulley Water pump pulley Drive belt idler pulley No.3 engine mount rubber and No.3 engine joint bracket (See B12 No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Removal Note) (See B16 No.3 Engine Mount Rubber and No.
TIMING CHAIN Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2212W004 4. Hold the crankshaft pully by using the SSTs. AME2215W002 Chain Tensioner Removal Note 1. Using a thin screwdriver, hold the chain tensioner ratchet lock mechanism away from the ratchet stem. 2. Slowly compress the tensioner piston. 3. Hold the tensioner piston using a 1.5 mm {0.
TIMING CHAIN Oil Pump Sprocket Removal Note 1. Hold the oil pump sprocket by using the SST. B AME2215W005 Engine Front Cover Removal Note 1. Remove the oil seal using a screwdriver as shown. AME2215W006 Oil Pump Sprocket Installation Note 1. Hold the oil pump sprocket by using the SST.
TIMING CHAIN Timing Chain Installation Note 1. Install the SST to the camshaft as shown. European countries Except European countries 2. Install the timing chain. 3. Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain. AME2212W010 AME2212W011 Engine Front Cover Installation Note 1. Apply silicone sealant to the engine front cover as shown. Caution • Install the cylinder head cover within 10 minutes of applying the silicone sealant.
TIMING CHAIN 2. Install the cylinder head cover bolts in the order as shown. Bolt No. Tightening torque 118 8.011.5 N·m {81.6117.2 kgf·cm, 70.9101.7 in·lbf} 1922 4055 N·m {4.15.6 kgf·m, 29.740.5 ft·lbf} B AME2215W008 Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Compress the oil seal using the SST and a hammer.
TIMING CHAIN No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Installation Note 1. Tighten the stud bolt of the No.3 engine mount bracket. Tightening torque: 7.013 N·m {71.4132.5 kgf·cm, 62.0115.0 in·lbf} 2. Install the No.3 engine mount rubber handtighten. AME2215W011 3. Tighten the No.3 engine joint bracket is attached and bolts, nuts in the order shown. AME2215W012 Crankshaft Pulley Lock Bolt Installation Note 1. Install the SST to the camshaft as shown.
TIMING CHAIN 2. Install the M6 x 1.0 bolt in by hand. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. B AME2215W013 4. Hold the crankshaft pully by using the SST. 5. Tighten the crankshaft pulley lock bolt using the following two steps. (1) Tighten to 96104 N·m {9.810.6 kgf·m, 70.976.7 ft·lbf} (2) Tighten 87°° 93°° 6. Remove the M6 x 1.0 bolt. 7. Remove the SST from the camshaft. 8. Remove the SST from the cylinder block lower blind plug. 9.
TIMING CHAIN, CYLINDER HEAD GASKET 3. Tighten the bolts in the order shown. Tightening torque: 8.011.5 N·m {81.6122.3 kgf·cm, 70.9 106.2 in·lbf} AME2215W015 End Of Sie CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT A6E221810271W01 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.
CYLINDER HEAD GASKET B AME2218W002 . 1 2 Camshaft (See B19 Camshaft Removal Note) (See B21 Camshaft Installation Note) Oil control valve (OCV) (L3) 3 4 Cylinder head (See B20 Cylinder Head Removal Note) (See B20 Cylinder Head Installation Note) Cylinder head gasket Camshaft Removal Note Note • The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. When removed, keep the caps with the cylinder head they were removed from.
CYLINDER HEAD GASKET 1. Loosen the camshaft cap bolts in several passes in the order shown. AME2212W008 Cylinder Head Removal Note 1. Loosen the cylinder head bolts in several passes in the order shown. AME2218W003 Cylinder Head Installation Note 1. Measure the length of each cylinder head bolt. • Replace any that exceed maximum length. Length L: 149.0150.0 mm {5.8675.905 in} Maximum: 150.5 mm {5.965 in} AME2218W004 2. Tighten the cylinder head bolts in the order shown using the following 5 steps.
CYLINDER HEAD GASKET, FRONT OIL SEAL Camshaft Installation Note 1. Set the cam position of the No.1 cylinder at the top dead center (TDC) and install the camshaft. 2. Temporarily tighten the camshaft bearing caps in two or three even movements. 3. Tighten the camshaft cap bolts in the order shown using the following two steps. (1) Tighten to 5.09.0 N·m {51.091.7 kgf·cm, 44.679.5 in·lbf} (2) Tighten to 14.017.0 N·m {1.51.7 kgf·m, 10.412.
FRONT OIL SEAL Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2212W004 4. Hold the crankshaft pulley by using the SSTs. AME2215W002 Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
FRONT OIL SEAL Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer. B AME2215W009 AME2215W010 Crankshaft Pulley Lock Bolt Installation Note 1. Install the SST to the camshaft as shown.
FRONT OIL SEAL 2. Install the M6 x 1.0 bolt in by hand. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2215W013 4. Hold the crankshaft pulley by using the SSTs. 5. Tighten the crankshaft pulley lock bolt in the order shown using the following two steps. (1) Tighten to 96104 N·m {9.810.6 kgf·m, 70.976.7 ft·lbf} (2) Tighten 87°° 93°° 6. Remove the M6 x 1.0 bolt. 7. Remove the SST from the camshaft. 8. Remove the SST from the cylinder block lower blind plug. 9.
REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. 2. 3. 4. Remove the flywheel. (MTX) (See H11 CLUTCH UNIT REMOVAL/INSTALLATION) Remove the drive plate. (ATX) (See K43 DRIVE PLATE REMOVAL/INSTALLATION) Remove in the order indicated in the table. Install in the reverse order of removal. A6E222211399W01 . 1 2 Bolt Rear oil seal (See B25 Rear Oil Seal Installation Note) AME2222W001 Rear Oil Seal Installation Note 1. Apply silicone sealant to the mating faces as shown. Dot diameter: 4.06.
ENGINE ENGINE ENGINE REMOVAL/INSTALLATION A6E222401001W01 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety Procedure. (See F17 Fuel Line Safety Procedure.) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
ENGINE B AME2213W001 . 1 2 No.1 Engine mount rubber (See B28 No.1 Engine Mount Rubber Removal Note) (See B31 No.1 Engine Mount Rubber Installation Note) No.1 Engine mount bracket (See B31 No.1 Engine Mount Bracket Installation Note) 3 4 5 6 No.4 Engine mount bracket and No.4 Engine mount rubber (See B28 No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Removal Note) (See B30 No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note) Engine ground No.
ENGINE No.1 Engine Mount Rubber Removal Note 1. Suspend the engine using the SSTs. 2. Remove the through bolt A on the No.1 engine mount bracket side. AME2215W004 3. Loosen the through bolt B on the chassis side until approximately three pitches are showing. Note • Do not remove the No.1 engine mount rubber from the vehicle. AME2213W002 AME2213W003 No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Removal Note 1. Secure the engine and the transaxle using an engine jack and attachment as shown.
ENGINE 2. Remove the SST. B AME2215W004 3. Secure the engine and the transaxle using a hoist. AME2213W004 4. No.4 engine mount bracket and engine mount rubber together in one piece. AME2213W005 No.3 Engine Joint Bracket Installation Note 1. Tighten the No.3 engine mount bracket stud bolt. Tightening torque: 7.013 N·m {71.4132.5 kgf·cm, 62.0115.
ENGINE 2. Tighten the No.3 engine joint bracket bolt and nut in the order shown. AME2213W010 No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note 1. Tighten the No.4 engine mount bracket and No.4 engine mount rubber bolt and nut in the order as shown. AME2213W011 2. Secure the engine and the transaxle using an engine jack and attachment as shown. AME2218W001 3. Remove the hoist and secure the engine and transaxle using SST.
ENGINE No.1 Engine Mount Bracket Installation Note 1. Tighten No.1 engine mount bracket bolt A. Tightening torque: 93.1116.6 N·m {9.5011.88 kgf·m, 68.72 85.92 ft·lbf} B 2. Tighten No.1 engine mount bracket bolt B. Tightening torque: 93.1116.6 N·m {9.5011.88 kgf·m, 68.72 85.92 ft·lbf} AME2213W008 No.1 Engine Mount Rubber Installation Note 1. Tighten through bolt A on No.1 engine mount bracket. Tightening torque: 85.3116.6 N·m {8.711.88 kgf·m, 62.93 85.92 ft·lbf} 2.
VARIABLE VALVE TIMING VARIABLE VALVE TIMING VARIABLE VALVE TIMING ACTUATOR INSPECTION L3 A6E222500142W01 Caution • Variable valve timing actuator can not be disassembled it is a precision unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Disconnect the negative battery cable. Remove the plug hole plate. Remove the high-tension lead. Remove the oil control valve connector. Remove the ventilation hose. Remove the cylinder head cover.
VARIABLE VALVE TIMING, OIL CONTROL VALVE (OCV) Variable Valve Timing Actuator Removal Note 1. Set a wrench or equivalent tool at the hexagonal part of the camshaft to prevent rotation. 2. Loosen the variable valve timing actuator tightening bolts. Variable Valve Timing Actuator Installation Note 1. Set a wrench or equivalent tool at the hexagonal part of the camshaft to prevent rotation. 2. Tighten variable valve timing actuator tightening bolts. B Tightening torque 6975N·m {7.107.6 kgf·m, 50.955.
OIL CONTROL VALVE (OCV) Spool Valve Operation Inspection 1. Disconnect the negative battery cable. 2. Remove the oil control valve. 3. Verify that the spool valve in the oil control valve is in the maximum valve timing retard position as indicated in the figure. • If not as specified, replace the oil control valve. 4. Verify that the battery is fully charged. • If not as specified, recharge the battery. 5.
LUBRICATION SYSTEM D LOCATION INDEX .................................................D-2 LOCATION INDEX...............................................D-2 OIL PRESSURE INSPECTION ..............................D-3 OIL PRESSURE INSPECTION............................D-3 ENGINE OIL ...........................................................D-4 ENGINE OIL INSPECTION..................................D-4 ENGINE OIL REPLACEMENT.............................D-4 OIL FILTER.............................................
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E330001002W01 AME3300W001 .
OIL PRESSURE INSPECTION OIL PRESSURE INSPECTION OIL PRESSURE INSPECTION A6E331001003W01 Warning • Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil. • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. 1. Remove the under cover. 2. Remove the oil pressure switch. 3.
ENGINE OIL ENGINE OIL ENGINE OIL INSPECTION 1. 2. 3. 4. 5. A6E331214001W01 Position the vehicle on level ground. Warm up the engine to normal operating temperature. Stop the engine and wait for 5 min. Remove the dipstick. Verify that the oil level is between the F and L marks on the dipstick and check the engine oil condition. • If the oil level is below the L mark, add the oil. End Of Sie ENGINE OIL REPLACEMENT A6E331214001W02 Warning • Hot engines and engine oil can cause severe burns.
ENGINE OIL Recommended engine oil Market Item Grade Viscosity (SAE) Remarks Europe API SJ ACEA A1 or A3 API SL ILSAC GF-3 5W-30 5W-20 Mazda genuine DEXELIA oil Except Europe API SG, SH, SJ, SL ILSAC GF-2, GF-3 40, 30, 20, 20W-20, 10W-30, 10W-40, 10W-50, 20W-40, 15W-40, 20W-50, 15W-50, 5W-20, 5W-30 7. Refit the oil filler cap. 8. Run the engine and inspect for oil leakage. 9. Inspect the oil level. • If necessary, add oil. (See D4 ENGINE OIL INSPECTION.) 10.
OIL FILTER OIL FILTER OIL FILTER REPLACEMENT For Europe (LF and L3 engine models) A6E331414300W01 Caution • To avoid damage to the oil filter, use only specified oil filter. 1. Remove the oil filter drain plug. 2. Untighten the oil filter cover for 2 turns and drain the engine oil. Note • Oil could be easily drained when the air is in the filter. AME3314W001 3. Remove the oil filter. 4. Use a clean rag to wipe off the mounting surface on the oil filter adapter and the oil filter cover. 5.
OIL COOLER OIL COOLER OIL COOLER REMOVAL/INSTALLATION A6E331819900W01 LF, L3 1. Remove the under cover. 2. Drain the engine coolant. (See E3 ENGINE COOLANT REPLACEMENT.) 3. Remove the oil filter cover, and drain the engine oil into a container. (See D6 OIL FILTER REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Use a clean rag to wipe off the mounting surface on the oil cooler. 6. Install in the reverse order of removal. 7. Inspect the oil level. • If necessary, add oil.
OIL PAN OIL PAN OIL PAN REMOVAL/INSTALLATION A6E332010040W01 Warning • Hot engine and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. 1. 2. 3. 4. 5. 6. 7. 8. Disconnect the negative battery cable. Remove the under cover. Drain the engine oil. (See D4 ENGINE OIL REPLACEMENT.) Remove the engine front cover. (See B10 TIMING CHAIN REMOVAL/INSTALLATION.) Remove in the order indicated in the table. Install in the reverse order of removal.
OIL PAN Oil Pan Installation Note 1. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side. D AME3320W002 2. Apply silicone sealant to the oil pressure switch threads as shown. AME3320W003 3. Tighten the bolts in the order shown.
OIL PUMP OIL PUMP OIL PUMP REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. Disconnect the negative battery cable. Drain the engine oil. (See D4 ENGINE OIL REPLACEMENT.) Remove the oil pan. (See D8 OIL PAN REMOVAL/INSTALLATION.) Remove in the order indicated in the table. Install in the reverse order of removal. Inspect the engine oil level. (See D4 ENGINE OIL INSPECTION.) Start the engine and inspect for oil leakage. • If the oil leaks, specify the faulty part and repair or replace it. 8.
OIL PUMP Oil Pump Sprocket Removal / Installation Note 1. Install the SST to the oil pump sprocket to stop the oil pump from turn in.
COOLING SYSTEM E LOCATION INDEX .................................................E-2 LOCATION INDEX.............................................. E-2 COOLING SYSTEM SERVICE WARNINGS ..........E-3 COOLING SYSTEM SERVICE WARNINGS ....... E-3 ENGINE COOLANT................................................ E-3 ENGINE COOLANT LEVEL INSPECTION..........E-3 ENGINE COOLANT REPLACEMENT .................E-3 ENGINE COOLANT LEAKAGE INSPECTION ....E-4 RADIATOR CAP.....................................................
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E360001002W01 AME3602N001 .
COOLING SYSTEM SERVICE WARNINGS , ENGINE COOLANT COOLING SYSTEM SERVICE WARNINGS COOLING SYSTEM SERVICE WARNINGS A6E361001004W01 Warning • Never remove the radiator cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. • Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
ENGINE COOLANT 9. Start the engine and let it idle until the cooling fan operates. 10. After engine warms up, perform the following steps. (1) Run the engine at 2,500 rpm for 5 min. (2) Run the engine at 3,000 rpm for 5 s, then return to idling. (3) Repeat Step (2) several times. (4) Run the engine at idle for 1 min. 11. Stop the engine and wait until it is cool. 12. Remove the radiator cap. 13. Check the coolant level. • If It is low, repeat Steps 69. 14. Install the radiator cap. 15.
RADIATOR CAP RADIATOR CAP RADIATOR CAP INSPECTION A6E361415201W01 Warning • Never remove the radiator cap while the engine is running, or when the engine and radiator are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. • Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop.
RADIATOR RADIATOR RADIATOR REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Disconnect the negative battery cable. Drain the engine coolant. (See E3 ENGINE COOLANT REPLACEMENT.) Remove the cooling fan. (See E9 COOLING FAN REMOVAL/INSTALLATION.) Remove the oil hose. (ATX) Remove in the order indicated in the table. Install in the reverse order of removal. Refill the engine coolant. (See E3 ENGINE COOLANT REPLACEMENT.) Inspect the engine coolant leakage. (See E4 ENGINE COOLANT LEAKAGE INSPECTION.
THERMOSTAT THERMOSTAT THERMOSTAT REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. Remove the plug hole plate. Disconnect the negative battery cable. Drain the engine coolant. (See E3 COOLING SYSTEM SERVICE WARNINGS.) Remove the drive belt. (See B3 DRIVE BELT REPLACEMENT.) Remove the washer tank. Remove the P/S oil pump. A6E361815171W01 E Note • Remove the P/S oil pump with hoses and pipe still connected. 7. 8. 9. 10. Remove in the order indicated in the table. Install in the reverse order of removal.
THERMOSTAT, WATER PUMP THERMOSTAT INSPECTION A6E361815171W02 1. Inspect the thermostat for the following. • Closed valve in room temperature • Opening temperature and lift of the valve If not as specified, replace the thermostat. Initial-opening temperature (°C {°F}) Full-open temperature (°C {°F}) Full-open lift (mm {in}) 80.084.0 {176183.2} 97 {206.6} More than 8.0 {0.31} End Of Sie WATER PUMP WATER PUMP REMOVAL/INSTALLATION A6E362015010W01 1. Disconnect the negative battery cable. 2.
FAN MOTOR End Of Sie FAN MOTOR COOLING FAN REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. Disconnect the negative battery cable. Remove the shroud panel. (See S119 SHROUD PANEL REMOVAL/INSTALLATION.) Remove the A/C pipe stay. Remove the ATX pipe stay (ATX). Remove in the order indicated in the table. Install in the reverse order of removal. A6E362215025W01 E 7.
FAN MOTOR COOLING FAN MOTOR REMOVAL/INSTALLATION 1. Remove the cooling fan. (See E9 COOLING FAN REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. A6E362215025W02 4. AME3621W002 1 2 Cooling fan No.2 Cooling fan No.1 End Of Sie E10 3 4 Cooling fan motor No.2 Cooling fan motor No.
FAN MOTOR COOLING FAN MOTOR INSPECTION 1. Verify that the battery is fully charged. 2. Connect battery positive voltage and an ammeter to the fan motor connector. 3. Verify that the fan motor operates smoothly at the standard current draw. • If not as spcifid, replace the fan motor. A6E362215025W03 E AME3621W003 Part name L8 Cooling fan motor No.1 6.6 Cooling fan motor No.2 6.6 Current (A) LF 6.6 (Except Israel) 10 (For Israel) 6.6(Except Israel) 10 (For Israel) L3 5.
FUEL AND EMISSION CONTROL SYSTEMS F LOCATION INDEX ................................................. F-3 INTAKE-AIR SYSTEM ......................................... F-3 FUEL SYSTEM .................................................... F-4 EMISSION SYSTEM............................................ F-6 CONTROL SYSTEM............................................ F-7 ENGINE TUNE-UP ................................................. F-8 IGNITION TIMING INSPECTION ........................
OBD DRIVE MODE............................................ F-64 DIAGNOSTIC MONITORING TEST RESULTS. F-65 DTC CONFIRMATION PROCEDURE ............... F-66 KOEO/KOER SELF-TEST ................................. F-66 AFTER REPAIR PROCEDURE ......................... F-66 DTC TABLE ....................................................... F-67 DTC P0010 ........................................................ F-70 DTC P0011 ........................................................ F-72 DTC P0012 .....................
LOCATION INDEX LOCATION INDEX INTAKE-AIR SYSTEM A6E390013000W01 F A6E3910W018 .
LOCATION INDEX End OfSYSTEM Sie FUEL Engine Room Side A6E390001006W01 A6E3912W015 F4
LOCATION INDEX Fuel tank side F A6E3912W045 .
LOCATION INDEX EMISSION SYSTEM A6E390001074W01 Engine room side A6E3916W017 . 1 2 3 EGR valve (See F39 EGR VALVE REMOVAL/ INSTALLATION) (See F40 EGR VALVE INSPECTION) Purge solenoid valve (See F38 PURGE SOLENOID VALVE REMOVAL/ INSTALLATION) (See F39 PURGE SOLENOID VALVE INSPECTION) Evaporative gas check valve (one-way) (L.H.D.) (See F38 EVAPORATIVE GAS CHECK VALVE (ONE-WAY) INSPECTION (L.H.D.
LOCATION INDEX CONTROL SYSTEM A6E390001074W02 F A6E3940W500 .
ENGINE TUNE-UP End Of Sie ENGINE TUNE-UP IGNITION TIMING INSPECTION A6E390802000W01 Note • Ignition timing is not adjustable. • Ignition timing verification requires WDS or equivalent. 1. Turn off the electrical loads. 2. Warm up the engine as follows. (1) Start the engine. (2) Maintain the engine speed at approx. 3,000 rpm until the cooling fans start to operate. (3) Release the accelerator pedal. (4) Wait until the cooling fans stop. 3.
ENGINE TUNE-UP Idle speed (LF engine ATX model) Condition Engine speed (rpm)*1 650750 Electrical loads*2 ON P/S ON A/C ON and refrigerant pressure switch (middle) OFF A/C ON and refrigerant pressure switch (middle) ON 650750 No load Idle speed (L3 engine model) 650750 650750 700800 F Condition Engine speed (rpm)*1 No load 600700 Electrical loads*2 ON P/S ON A/C ON and refrigerant pressure switch (middle) OFF A/C ON and refrigerant pressure switch (middle) ON 650750 650750 700800 70080
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM A6E391020030W01 A6E3910W034 End Of Sie SYSTEM REMOVAL/INSTALLATION INTAKE-AIR A6E391013000W01 Warning • When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous.
INTAKE-AIR SYSTEM 4. Complete the AFTER REPAIR PROCEDURE. (See F17 AFTER REPAIR PROCEDURE.) .
INTAKE-AIR SYSTEM Resonance Chamber Removal Note 1. Remove the front mudguard (LH) before removing the resonance chamber. Vacuum Hose (Purge Solenoid Valve) Installation Note 1. Fit the vacuum hose (purge solenoid valve) onto the respective fittings, and install clamps as shown. A6E3910W021 End Of Sie AIR DUCT (VAD) SHUTTER VALVE INSPECTION (L3) VARIABLE 1. Remove the air cleaner case. (See F10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Disconnect the vacuum hose from the VAD shutter valve actuator. 3.
INTAKE-AIR SYSTEM VARIABLE AIR DUCT (VAD) CONTROL SOLENOID VALVE INSPECTION (L3) A6E391013000W03 1. Remove the VAD control solenoid valve. (See F10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Inspect airflow between the ports under the following conditions. • If not as specified, replace the VAD control solenoid valve. • If as specified, carry out the Circuit Open/ Short Inspection. F A6E3910W036 A6E3910W037 Circuit Open/Short Inspection 1. Disconnect the PCM connector.
INTAKE-AIR SYSTEM 2. Disconnect the IAC valve connector. 3. Measure the resistance between the IAC valve terminals using an ohmmeter. • If not as specified, replace the IAC valve. (See F10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) • If as specified but the Operation Test is failed, carry out the Circuit Open/Short Inspection. Specification Ambient temperature (°°C {°°F}) 23 {73} Resistance (ohms) 8.810.6 Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F43 PCM REMOVAL/INSTALLATION.
INTAKE-AIR SYSTEM Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following wiring harness for open or short (continuity check). Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness.
INTAKE-AIR SYSTEM 2. Inspect the following wiring harness for open or short (continuity check). Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. Variable tumble control solenoid valve terminal B (harness-side) and PCM terminal 4T Variable tumble control solenoid valve terminal A (harness-side) and main relay terminal C (harness-side) Short circuit • If there is continuity, the circuit is shorted. Repair or replace the harness.
FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE A6E391201006W01 Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following Fuel Line Safety Procedure.
FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION A6E391242110W01 Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes.
FUEL SYSTEM Breather Hose Installation Note 1. Fit the breather hose onto the respective fittings, and install clamps as shown. F A6E3912W038 Joint Hose Installation Note 1. Fit the joint hose onto the respective fittings, and install clamps as shown. A6E3912W034 End OfTANK Sie INSPECTION FUEL A6E391242110W02 Caution • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector.
FUEL SYSTEM 8. Turn the fuel tank upside-down and apply pressure of 2.0 kPa {15 mmHg, 0.6 inHg} to port A. (1) Plug port C and verify there is no vacuum from port B. • If there is vacuum, replace the fuel tank. A6E3912W046 End Of Sie VALVE INSPECTION NONRETURN 1. Remove the fuel pump unit. (See F22 FUEL PUMP UNIT REMOVAL/INSTALLATION.) 2. Siphon the fuel from the fuel tank. A6E391242270W01 Note • Nonreturn valve is integrated in the fuel tank.
FUEL SYSTEM Note • The stopper may be removed from the quick connector. Take care not to loose it. Reinstall it to the quick release connector before reconnecting the fuel line. F A6E3912W001 • The locking coupler has two internal locking tabs which retain the pulsation damper pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs. 4. Push the SST quick release connector into the fuel pipe and plastic fuel hose into the SST until a click is heard.
FUEL SYSTEM 13. Complete the BEFORE REPAIR PROCEDURE. (See F17 BEFORE REPAIR PROCEDURE) 14. Disconnect the SST. Note • A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe. 15. Inspect the plastic fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
FUEL SYSTEM Plastic Fuel Hose Removal Note Caution • The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab over the stopper. 1. Disconnect the quick release connector. (1) Push the tab on the locking coupler 90 degrees until it stops. (2) Pull the fuel hose straight back. Note • The stopper may be removed from the quick connector. Take care not to lose it. Reinstall it to the quick release connector before reconnecting the fuel line.
FUEL SYSTEM Fuel Pump Unit Installation Note 1. Verify that the fuel tank mark is aligened with the fuel pump mark as shown. A6E3912W026 Plastic Fuel Hose Installation Note Note • A checker tab is integrated with quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe. 1. When the retainer is not removed, perform the following procedure.
FUEL SYSTEM 2. Assemble in the reverse order of disassembly. 1 2 3 . Packing Fuel pump unit Fuel gauge sender unit F A6E3912W025 End OfPUMP Sie UNIT INSPECTION FUEL A6E391213350W03 Caution • It is normal to hear the fuel pump operating when the ignition switch is turned to the ON position. Note • To improve startability, the fuel pump control operates the fuel pump unit when the ignition switch is turned to the ON position.
FUEL SYSTEM Fuel Pump Hold Pressure Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Caution • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector.
FUEL SYSTEM 5. Cover the disconnected quick release connector with vinyl sheet or the like to prevent it from being scratched or contaminated with foreign material. A6E3912W021 6. Turn the lever 90 degrees against the hose of the SST to plug the SST outlet. 7. Push the SST quick release connector into the fuel pipe until a click is heard. 8. Set the fuel hose into a container to avoid fuel spills. 9. Connect the negative battery cable.
FUEL SYSTEM End OfINJECTOR Sie FUEL REMOVAL/INSTALLATION A6E391213250W01 Caution • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material. 1. Complete the BEFORE REPAIR PROCEDURE. (See F17 BEFORE REPAIR PROCEDURE.) 2.
FUEL SYSTEM • The locking coupler has two internal locking tabs which retain the fuel pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs. A6E3912W002 2. Cover the disconnected quick release connector and fuel pipe with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material.
FUEL SYSTEM (2) Pull the clip parallel to the injector groove, and remove it from the injector. (3) Discard the clip. A6E3912W042 Fuel Injector Installation Note 1. Lightly lubricate the injector groove and O-ring. 2. Pre-attach a new clip in the injector groove. Note • When the clip is attached correctly, the central area of the injector and the clip finger positions are aligned. 3. Hold the injector firmly, push the clip into the injector until the clip stops sliding. 4.
FUEL SYSTEM (4) Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.03.0 mm {0.080.11 in} and it is connected securely. • If quick release connector does not move at all, verify that O-ring is not damaged and slipped, and reconnect the quick release connector. 2. When the retainer is removed, perform the following procedure. End Of Sie FUEL INJECTOR INSPECTION A6E391213250W02 Operation Test 1. Carry out the Fuel Injector Operation Inspection.
FUEL SYSTEM No.2 cylinder fuel injector terminal A (harness-side) and power supply. No.3 cylinder fuel injector terminal A (harness-side) and power supply. No.4 cylinder fuel injector terminal A (harness-side) and power supply. Fuel Leakage Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • Perform the following test only when directed. 1.
FUEL SYSTEM Volume Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • If there is an after market fuel injector tester, perform the following test. • If there is no an after market fuel injector tester, perform Operation Test, Resistance Inspection, and Fuel Leakage Test to verify the fuel injector is okay or not. 1. 2. 3. 4. 5.
FUEL SYSTEM PRESSURE REGULATOR INSPECTION A6E391213280W01 Note • Due to the adoption of the mechanical returnless fuel system, the pressure regulator cannot be inspected separately. 1. Perform FUEL LINE PRESSURE INSPECTION. (See F20 FUEL LINE PRESSURE INSPECTION.) End Of Sie PULSATION DAMPER REMOVAL/INSTALLATION A6E391220180W01 1. Remove and install the pressure regulator.(See F28 FUEL INJECTOR REMOVAL/INSTALLATION.) End Of Sie PULSATION DAMPER INSPECTION A6E391220180W02 1.
EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. • If leakage is found, repair or replace as necessary. A6E391440000W01 End Of Sie EXHAUST SYSTEM REMOVAL/INSTALLATION A6E391440000W02 Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2.
EXHAUST SYSTEM A6E3914W002 .
EXHAUST SYSTEM 1 2 3 4 5 6 Main silencer Middle pipe TWC Exhaust manifold insulator (upper) Bracket Exhaust manifold (See F37 Exhaust Manifold Installation Note) 7 8 9 10 Exhaust manifold gasket Exhaust manifold insulator (lower) HO2S (front) (See F37 HO2S Removal Note) HO2S (rear) (See F37 HO2S Removal Note) HO2S Removal Note 1. Remove the HO2S using the SST before removing the exhaust manifold. F A6J3914W004 Exhaust Manifold Installation Note 1.
EMISSION SYSTEM EMISSION SYSTEM CHARCOAL CANISTER INSPECTION A6E391613970W01 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel tank side port and verify that there is no air leakage. • If there is air leakage, replace the charcoal canister. A6E3916W002 End Of Sie EVAPORATIVE GAS CHECK VALVE (ONE-WAY) INSPECTION (L.H.D.) 1. Remove the evaporative gas check valve (one-way). 2.
EMISSION SYSTEM PURGE SOLENOID VALVE INSPECTION A6E391618740W02 Airflow Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. (See F38 PURGE SOLENOID VALVE REMOVAL/INSTALLATION.) 3. Inspect airflow between the ports under the following conditions. • If not as specified, replace the purge solenoid valve. • If as specified, carry out the Circuit Open/Short Inspection.
EMISSION SYSTEM EGR VALVE INSPECTION Operation Test 1. Carry out the EGR Control Inspection. (See F233 EGR Control System Inspection. • If not as specified, perform the further inspection for the EGR valve. A6E391620300W02 Resistance Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Inspect resistance of the EGR valve coils. • If not as specified, replace the EGR valve. • If as specified, carry out the Circuit Open/ Short Inspection.
EMISSION SYSTEM PCV VALVE INSPECTION 1. 2. 3. 4. Disconnect the negative battery cable. Remove the intake maniforld.(see F10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) Remove the PCV valve. Blow through the valve and verify that air flows as specified. • If not as specified, replace the PCV valve.
EMISSION SYSTEM Upstream HO2S graph line example A6E3916W021 Downstream HO2S graph line example 1 Equation RATIO = 30 inversions (upstream HO2S inversions) ÷ 5 inversions (downstream HO2S inversions) = 6.0 (good WU-TWC) A6E3916W012 Downstream HO2S graph line example 2 A6E3916W014 Downstream HO2S graph line example 3 Equation RATIO = 30 inversions (upstream HO2S inversions) ÷ 27 inversions (downstream HO2S inversions) = 1.
CONTROL SYSTEM CONTROL SYSTEM PCM REMOVAL/INSTALLATION A6E394018880W01 Note • For replace the PCM, Setup the WDS and perform the PCM configuration. (See F50 PCM CONFIGURATION.) 1. Disconnect the negative battery cable. 2. For R.H.D, perform the following procedures. (1) Remove the front side trim (left-side). (2) Partially peel back the flower covering. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. U.K. specs. F A6E3940W002 . 1 PCM cover No.
CONTROL SYSTEM European (L.H.D.) specs. A6E3940W001 . 1 2 PCM cover PCM connector 3 PCM Set Nut/bolt Removal Note 1. Using a chisel and a hammer, cut a groove on the head of the set nut/bolt so that a screwdriver can be inserted. 2. Loose the set nut/bolt using an impact screwdriver or pliers. A6E3940W003 Set Nut/bolt Installation Note 1. Install a new set nut/bolt and tighten it until the neck of the nut/bolt is cut.
CONTROL SYSTEM PCM INSPECTION A6E394018880W02 Note • PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. CMP sensor (See F55 CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) Main relay (See T24 RELAY INSPECTION.) 1. Connect the SST (WDS or equivalent) to the DLC-2. 2. Turn the ignition switch to ON position. 3. Measure the PID value. • If PID value is not within the specification, follow the instructions in Action column.
CONTROL SYSTEM Monitor item (Definition) Unit/ Condition Condition/Specification (Reference) Action PCM terminal Inspect following PIDs: IAT, RPM, MAP, ECT, MAF, TP, INGEAR, ACSW, TR, PSP, ALTT V. Inspect IAC valve. (See F13 IDLE AIR CONTROL (IAC) VALVE INSPECTION) Inspect CKP sensor.
CONTROL SYSTEM Monitor item (Definition) FDPDTC (Pending code caused FFD storage) FP (Fuel pump relay) FUELPW (Fuel injector duration) FUELSYS (Fuel system status) GENVDSD (Generator voltage desired) Unit/ Condition ON/OFF HTR12 (HO2S heater (rear)) ON/OFF IAC (IAC valve) IAT (Intake air temperature) Action Perform applicable DTC troubleshooting. (See F67 DTC TABLE) Ignition switch ON: OFF Inspect following PIDs: RPM. ON/OFF Idle: ON Inspect fuel pump relay.
CONTROL SYSTEM Monitor item (Definition) Unit/ Condition Condition/Specification (Reference) KNOCKR (Knocking retard) ANGLE LOAD (Engine load) % Ignition switch ON: 0% Idle (after warm up): approx.19% LONGFT1 (long term fuel trim) % Idle (after warm up): approx.14 14% MAF (Mass airflow) MAP (Manifold absolute pressure) g/s V Pressure V Ignition switch ON: 0 DEG Idle: 0 DEG Ignition switch ON: approx. 0 g/s Idle (after warm up): 1.5 g/s Ignition switch ON: approx. 0.
CONTROL SYSTEM Monitor item (Definition) SEGRP (EGR valve (stepping motor) position) Unit/ Condition STP SHRTFT1 (Short term fuel trim) % SPARKADV (Ignition timing) BTC TEST (Test mode) TP (TP) ON/OFF % V Condition/Specification (Reference) Ignition switch ON: 0 step Idle: 0 step Cranking: 060 steps Idle (after warm up): approx.30 25% Ignition switch ON: BTDC 0° Idle: BTDC approx. 10° CTP: 1323% WOT: 8696% CTP: 0.651.15 V WOT: 4.34.8 V TPCT (TP sensor voltage at CTP ) V 0.651.
CONTROL SYSTEM PCM CONFIGURATION 1. Connect the WDS to DLC-2. 2. Set up the WDS (including the vehicle recognition.) 3. Select Module programming. 4. Select Programmable module installation. 5. Select PCM and perform procedures according to directions on the WDS screen. Note • If PCM CONFIGURATION is successful, the PCM stores the DTC P0602 and illuminates the MIL. (System is normal.) Clear the DTC P0602 using WDS or equivalent after PCM CONFIGURATION.
CONTROL SYSTEM MASS AIR FLOW (MAF) SENSOR INSPECTION Voltage Inspection A6E394013210W01 Note • Perform the following inspection only when directed. 1. Visually inspect for the following on the MAF sensor. • Damage • Cracks • Terminal bends • Terminal rust If any of the above are found, replace the MAF sensor. If the MAF PID value is out of specification, carry out the Circuit Open/Short Inspection. Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F43 PCM REMOVAL/INSTALLATION.) 2.
CONTROL SYSTEM Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following wiring harnesses for open or short. (Continuity check) Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness.
CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION A6E394018840W01 Warning • When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing the ECT sensor. 1. 2. 3. 4. Drain the engine coolant. (See E3 COOLING SYSTEM SERVICE WARNINGS.) Disconnect the ECT sensor connector. Remove the ECT sensor. Install in the reverse order of removal. F Tightening torque 1014 N·m {1.021.42 kgf·m, 7.3810.32 ft·lbf} 5. Refill the engine coolant.
CONTROL SYSTEM ECT sensor terminal B (harness-side) and power supply End Of Sie CRANKSHAFT POSITION (CKP) SENSOR INSPECTION A6E394018230W01 Note • Perform the following inspection only when directed. Resistance Inspection 1. Disconnect the CKP sensor connector. 2. Measure the resistance between CKP sensor terminals A and B using an ohmmeter. • If not as specified, replace the CKP sensor.
CONTROL SYSTEM (2) Remove the cylinder block lower blind plug and install the SST. (3) Turn the crankshaft pulley to the clockwise until it stops. 2. Install the CKP sensor to the CKP sensor installer. 3. Fit the forked part of the CKP sensor installer with the ninth tooth (counting counterclockwise from the empty space) of the pulse wheel. 4. Install the CKP sensor fitting bolts. Tightening torque 5.57.5 N·m {5676 kgf·cm, 4.15.5 ft·lbf} A6E3940W013 5. Remove the CKP sensor installer 6.
CONTROL SYSTEM KNOCK SENSOR INSPECTION A6E394018921W01 Note • Perform the following test only when directed. Resistance Inspection 1. Turn the ignition switch to LOCK. 2. Disconnect the knock sensor connector. 3. Measure the resistance between the knock sensor terminals A and B using an ohmmeter. • If not as specified, replace the knock sensor. • If the knock sensor is okay, but PID value is out of specification, perform the Circuit Open/Short Inspection. Specification Approx. 4.
CONTROL SYSTEM 3. Connect the voltmeter test leads to the following HO2S terminals: • HO2S (front and rear) (+) leadterminal A () leadterminal B 4. With the vehicle stopped, run the engine at 3,000 rpm until the voltmeter moves between 0.5 and 0.7 V. 5. Verify that the measurement voltage changes when the engine speed increases and decreases suddenly several times. • If not as specified, replace the HO2S.
CONTROL SYSTEM Circuit Open/Short Inspection (Heater) 1. Disconnect the PCM connector. (See F43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following wiring harnesses for open or short. (Continuity check) Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness.
CONTROL SYSTEM CLUTCH SWITCH INSPECTION A6E394018660W01 Note • Perform the following inspection only when directed. Continuity Inspection 1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch. 4. Inspect for continuity between the clutch switch terminals using an ohmmeter. • If the clutch switch is okay, but CPP PID value is out of specification, carry out of the Clutch Switch Circuit Open/Short Inspection.
CONTROL SYSTEM Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See F43 PCM REMOVAL/INSTALLATION.) 2. Inspect the following harness for open or short.
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD A6E397018881W01 • When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. If a DTC exists, diagnose the applicable DTC inspection. (See F67 DTC TABLE.) If no DTC exists and the MIL does not illuminate or flash, diagnose the applicable symptom troubleshooting. (See F181 ENGINE SYMPTOM TROUBLESHOOTING.
ON-BOARD DIAGNOSTIC OBD PENDING TROUBLE CODES A6E397018881W02 • These appear when a problem is detected in a monitored system. 2 Drive Cycle Type • The code for a failed system is stored in the PCM memory in the first drive cycle. If the problem is not found in the second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code.
ON-BOARD DIAGNOSTIC Pending Trouble Code Access Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect WDS or equivalent to the vehicle DLC-2 16-pin connector located as shown in the figure. 3. Retrieve PENDING TROUBLE CODES by WDS or equivalent. F A6E3970W002 Freeze Frame PID Data Access Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect WDS or equivalent to the vehicle DLC-2 16-pin connector located as shown in the figure. 3.
ON-BOARD DIAGNOSTIC OBD DRIVE MODE A6E397018881W09 • Performing the Drive Mode inspects the OBD system for proper operation. The Drive Mode must be performed to ensure that no additional DTCs are present. • During Drive Mode, the following systems are inspected: Oxygen sensor (HO2S) Oxygen sensor heater Catalytic converter (TWC) Caution • While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
ON-BOARD DIAGNOSTIC For MTX Zone O A B C D E F Shift Position Neutral 2nd 3rd 2nd 3rd 4th 5th Vehicle Speed Time km/h {mph} Sec.
ON-BOARD DIAGNOSTIC DTC CONFIRMATION PROCEDURE STEP INSPECTION 1 RECORD CONTINUOUS MEMORY DTC AND FREEZE FRAME DATA • Turn ignition key to ON (Engine OFF). • Connect WDS or equivalent to DLC. • Retrieve all stored DTCs. • Are there any DTCs present? 2 VERIFY RELATED REPAIR INFORMATION • Check for related Service information availability. • Is any related repair information available? 3 4 PERFORM KEY ON ENGINE OFF (KOEO) SELF-TEST • Start engine. • Warm up engine completely.
ON-BOARD DIAGNOSTIC DTC TABLE A6E397018881W14 DTC table DTC No.
ON-BOARD DIAGNOSTIC DTC No.
ON-BOARD DIAGNOSTIC DTC No.
ON-BOARD DIAGNOSTIC DTC P0010 DTC P0010 DETECTION CONDITION POSSIBLE CAUSE A6E397001084W01 CMP actuator circuit • PCM monitors OCV voltage. If PCM detects OCV control voltage (calculated from OCV) is above or below the threshold voltage (calculated from battery positive voltage), PCM determines that OCV circuit has malfunction. Diagnostic support note • • • • • • • • • • • • This is a continuous monitor (CCM). MIL illuminates if PCM detects the above malfunction condition during first drive cycle.
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 CLASSIFY MALFUNCTION AT POWER SUPPLY CIRCUIT OR CONTROL CIRCUIT • Turn ignition key to ON (Engine OFF). • Measure voltage between OCV terminal B (harness-side) and body GND. • Is voltage B+? 5 INSPECT CONTROL CIRCUIT FOR SHORT TO POWER • Turn ignition key to ON (Engine OFF). • Measure voltage between OCV terminal A (harness-side) and body GND. • Is voltage B+? 6 INSPECT CONTROL CIRCUIT FOR SHORT TO GND • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC DTC P0011 DTC P0011 DETECTION CONDITION POSSIBLE CAUSE A6E397001084W02 CMP - Timing over-advanced • Actual valve timing is over-advanced by 30 deg. from target valve timing when the OCV is controlled in the maximum valve timing retard condition. Diagnostic support note • • • • • • • • • • This is a continuous monitor (CCM). MIL illuminates if PCM detects the above malfunction condition during first drive cycles.
ON-BOARD DIAGNOSTIC DTC P0012 DTC P0012 DETECTION CONDITION POSSIBLE CAUSE A6E397001084W03 CMP - Timing over-retarded • Actual valve timing is over-retarded by 5 deg. from target valve timing for 5 s when the OCV system control is within feed-back range. Diagnostic support note • • • • • • • • • • This is a continuous monitor (CCM). MIL illuminates if PCM detects the above malfunction condition during first drive cycles. PENDING CODE is available if PCM detects the above malfunction condition.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 VERIFY TROUBLESHOOTING OF DTC P0012 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent. • Perform KOER self-test. (See F66 KOEO/KOER SELF-TEST.) • Is same DTC present? 8 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? ACTION Yes Replace PCM, then go to next step. (See F43 PCM REMOVAL/INSTALLATION.) No Go to next step.
ON-BOARD DIAGNOSTIC DTC P0031 Front HO2S heater circuit low input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF FRONT Yes Repair or replace terminal, then go to Step 8.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT CONTROL CIRCUIT OF FRONT HO2S HEATER FOR SHORT TO GROUND • Inspect continuity between front HO2S terminal D (harness-side) and body ground. • Is there continuity? 7 INSPECT CONTROL CIRCUIT OF FRONT HO2S HEATER FOR OPEN CIRCUIT • Remove PCM with PCM connector connected. • Inspect continuity between front HO2S terminal D (harness-side) and PCM terminal 4A.
ON-BOARD DIAGNOSTIC DTC P0032 Front HO2S heater circuit high input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT FRONT HO2S TERMINALS Yes Repair or replace terminal, then go to Step 6.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 VERIFY TROUBLESHOOTING OF DTC P0032 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent. • Perform KOEO/KOER self-test. (See F66 KOEO/KOER SELF-TEST.) • Is same DTC present? 7 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Of Sie DTC P0037 DTC P0037 POSSIBLE CAUSE F78 Yes Go to applicable DTC troubleshooting.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF REAR HO2S Yes Repair or replace terminal, then go to Step 8. CONNECTOR No Go to next step. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC DTC P0038 DTC P0038 A6E397001084W07 Rear HO2S heater circuit high input • PCM monitors rear HO2S heater control signal at PCM terminal 4D. If PCM turns rear HO2S heater on but rear HO2S heater circuit has high voltage, PCM determines that rear HO2S heater circuit has malfunction. Diagnostic support note DETECTION CONDITION POSSIBLE CAUSE • This is a continuous monitor (O2 sensor heater).
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT PCM TERMINAL • Disconnect PCM connector. • Inspect for bent terminals. • Is there any malfunctions? 5 INSPECT REAR HO2S HEATER CONTROL CIRCUIT FOR SHORT TO POWER • Turn ignition key to ON (Engine OFF). • Measure voltage between rear HO2S terminal D (harness-side) and body ground. • Is there voltage B+? 6 VERIFY TROUBLESHOOTING OF DTC P0038 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 VERIFY CURRENT INPUT SIGNAL STATUS-IS CONCERN INTERMITTENT OR CONSTANT • Connect WDS or equivalent to DLC-2. • Start the engine. • Access ECT, TP and MAF PIDs. • Warm up the engine until ECT PID is above 80 °C {176 °F}. • Drive the vehicle. • Read MAF PID while TP PID is above 50%. • Is MAF PID reading below 4.8 g/s {0.63 lb/ min.}? 4 VERIFY CURRENT INPUT SIGNAL STATUS-IS CONCERN INTERMITTENT OR CONSTANT • Connect WDS or equivalent to DLC-2. • Start the engine.
ON-BOARD DIAGNOSTIC STEP INSPECTION 10 VERIFY TROUBLESHOOTING OF DTC P0101 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from memory using WDS or equivalent. • Start the engine. • Warm up engine until ECT PID is above 80 °C {176 °F}. • Drive the vehicle while RPM PID 2,000 rpm for 50 s. • Is pending code the same as DTC present? 11 VERIFY AFTER REPAIR PROCEDURE • Is there any DTC present? ACTION Yes Replace PCM, then go to next step.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF MAF Yes Repair or replace terminals, then go to Step 7. SENSOR CONNECTOR No Go to next step. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC DTC P0103 DTC P0103 DETECTION CONDITION POSSIBLE CAUSE A6E397001084W10 MAF circuit high input • PCM monitors input voltage from MAF sensor when engine running. If input voltage at PCM terminal 1P is above 4.9 V, PCM determines that MAF circuit has malfunction. Diagnostic support note • • • • • • • • • This is a continuous monitor (CCM). MIL illuminates if PCM detects the above malfunction condition during first drive cycle.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 INSPECT MAF SIGNAL CIRCUIT FOR SHORT TO POWER CIRCUIT • Turn ignition key to ON (Engine OFF). • Measure voltage between MAF/IAT sensor terminal C (harness-side) and body ground. • Is there voltage 0 V? 4 INSPECT POOR CONNECTION OF PCM CONNECTOR • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.).
ON-BOARD DIAGNOSTIC DTC P0107 MAP sensor circuit low input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 VERIFY MAP PID WHEN MAP SENSOR Yes Go to next step. CONNECTOR IS DISCONNECTED No Go to step 4.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT MAP SENSOR SIGNAL AND GROUND CIRCUIT FOR SHORT EACH OTHER • Check continuity between MAP sensor terminals D and A (harness-side). • Is there continuity? 6 VERIFY TROUBLESHOOTING OF DTC P0107 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from memory using WDS or equivalent. • Perform KOEO/KOER self-test. (See F66 KOEO/KOER SELF-TEST.
ON-BOARD DIAGNOSTIC DTC P0108 MAP sensor circuit high input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT CONNECTION OF MAP SENSOR Yes Go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 VERIFY MAP SENSOR SIGNAL CIRCUIT FOR SHORT TO CONSTANT VOLTAGE CIRCUIT • Inspect for continuity between MAP sensor terminal D and C (harness-side). • Is there any continuity? 7 VERIFY MAP SENSOR SIGNAL CIRCUIT FOR OPEN CIRCUIT • Inspect continuity between MAP sensor terminal D (harness-side) and PCM terminal 1J (harness-side). • Is there any continuity? 8 VERIFY TROUBLESHOOTING OF DTC P0108 COMPLETED • Make sure to reconnect all disconnected connectors.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT POOR CONNECTION OF PCM CONNECTOR • Disconnect PCM connector. • Inspect for poor connection (damaged, pulledout pins, corrosion, etc.). • Are there any malfunction? 6 VERIFY TROUBLESHOOTING OF DTC P0111 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent. • Start engine and run engine under FREEZE FRAME DATA condition.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT IAT SENSOR TERMINAL Yes Repair or replace terminal, then go to Step 6. • Turn ignition key to OFF. No Go to next step.
ON-BOARD DIAGNOSTIC DTC P0113 IAT circuit high input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF IAT Yes Repair or replace terminal, then go to Step 8.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT POOR CONNECTION OF PCM CONNECTOR • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect PCM terminals 2E and 2H (harnessside) for tightness using feeler tool. • Are there any malfunction? 6 INSPECT IAT SENSOR SIGNAL CIRCUIT FOR OPEN CIRCUIT • Inspect continuity between MAF/IAT sensor terminal D (harness-side) and PCM terminal 2E.
ON-BOARD DIAGNOSTIC DTC P0117 ECT circuit low input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT TERMINAL BENT Yes Repair or replace terminal, then go to Step 6. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 VERIFY TROUBLESHOOTING OF DTC P0117 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent. • Perform KOEO/KOER self-test. (See F66 KOEO/KOER SELF-TEST.) • Is same DTC present? 7 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? ACTION Yes Replace PCM, then go to next step. (See F43 PCM REMOVAL/INSTALLATION.) No Go to next step.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF ECT Yes Repair or replace terminal, then go to Step 8. SENSOR CONNECTOR No Go to next step. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC DTC P0121 DTC P0121 A6E397001084W18 Throttle position stuck close (lower than expected)/open (higher than expected) • If PCM detects that throttle valve opening angle is below 12.5% for 5 s after following conditions are met, PCM determines that TP is stuck closed: MONITORING CONDITION Engine coolant temperature above 80 °C {176 °F} MAF sensor signal above 32.0 g/s {4.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 VERIFY CURRENT INPUT SIGNAL STATUS - IS CONCERN INTERMITTENT OR CONSTANT • Drive the vehicle and read MAF PID. • Does MAF PID change in compliance with driving condition? 7 8 9 10 11 12 13 14 INSPECT TP SENSOR TERMINALS FOR ELECTRICAL CORROSION • Turn ignition key to OFF. • Disconnect TP sensor connector • Inspect for electrical corrosion on male and female TP sensor terminals.
ON-BOARD DIAGNOSTIC STEP INSPECTION 15 INSPECT PCM TERMINALS FOR ELECTRICAL CORROSION • Disconnect PCM connector. • Inspect for electrical corrosion on PCM and PCM connector male and female terminals. • Is any electrical corrosion found? 16 VERIFY TROUBLESHOOTING OF DTC P0121 COMPLETED • Make sure to reconnect all disconnected connectors. • Start engine. • Clear DTC from PCM memory using WDS or equivalent. • Access RPM, TP and MAF PIDs using WDS or equivalent.
ON-BOARD DIAGNOSTIC DTC P0122 TP circuit low input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 CLASSIFY TP SENSOR OR HARNESS Yes Go to next step. MALFUNCTION No Go to step 4. • Connect WDS or equivalent.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 VERIFY TP SIGNAL CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Inspect continuity between TP sensor terminal B (harness-side) and PCM terminal 2A. • Is there continuity? 6 VERIFY TP SIGNAL CIRCUIT FOR SHORT TO GROUND • Inspect continuity between TP sensor terminal B (harness-side) and body ground. • Is there continuity? 7 VERIFY TROUBLESHOOTING OF DTC P0122 COMPLETED • Make sure to reconnect all disconnected connectors.
ON-BOARD DIAGNOSTIC DTC P0123 TP circuit high input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT TP SENSOR CONNECTOR Yes Go to next step. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 INSPECT PCM CONNECTOR • Disconnect PCM connector. • Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.). • Is there any malfunction? 8 VERIFY TP SIGNAL CIRCUIT FOR SHORT TO CONSTANT VOLTAGE CIRCUIT • Inspect continuity between TP sensor connector terminals B and C. • Is there continuity? 9 VERIFY TROUBLESHOOTING OF DTC P0123 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT ECT SENSOR • Inspect ECT sensor. (See F53 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.) • Is it okay? 6 INSPECT POOR CONNECTION OF PCM CONNECTOR • Disconnect PCM connector. • Inspect for poor connection (damaged, pulledout pins, corrosion, etc.). • Are there any malfunctions? 7 VERIFY TROUBLESHOOTING OF DTC P0125 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent.
ON-BOARD DIAGNOSTIC STEP INSPECTION 2 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Information availability. • Is any related Service Information available? 3 VERIFY RELATED PENDING AND STORED DTCs • Turn ignition key to OFF, then ON (Engine OFF). • Verify pending and stored DTCs using WDS or equivalent.
ON-BOARD DIAGNOSTIC STEP INSPECTION 12 INSPECT FUEL LINE FROM FUEL PUMP TO FUEL DELIVERY PUMP • Visually inspect fuel line for any leakage. • Is any fuel leakage found? 13 14 15 16 17 18 CHECK IGNITION COIL OPERATION • Perform spark test. (See F232 Spark Test) • Do all cylinders show blinking condition? INSPECT POWER SUPPLY TERMINAL AT IGNITION COIL CONNECTOR • Disconnect ignition coil connector. • Turn ignition key to ON (Engine OFF).
ON-BOARD DIAGNOSTIC STEP INSPECTION 19 VERIFY TROUBLESHOOTING OF DTC P0131 or P0132 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from memory using WDS or equivalent. • Start engine. • Access ECT and RPM PIDs using WDS or equivalent. • Make sure that ECT PID is above 80 °C {176 °F}. • Increase and keep engine speed above 1,500 rpm for at least 1 min.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 VERIFY RELATED PENDING AND STORED DTCS • Turn ignition key to OFF, then ON (Engine OFF). • Verify pending and /or stored DTCs using WDS or equivalent. • Is DTC P0443 also present? 4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA • Is DTC P0133 on FREEZE FRAME DATA? 5 6 7 8 9 10 11 VERIFY CURRENT INPUT SIGNAL STATUS • Warm up engine. • Access O2S11 PID using WDS or equivalent. • Inspect PID under following accelerator pedal conditions (in PARK (ATX) or NEUTRAL (MTX)).
ON-BOARD DIAGNOSTIC STEP INSPECTION 12 INSPECT SEALING OF ENGINE COOLANT PASSAGE Warning • Removing radiator cap when radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing radiator cap, wrap a thick cloth around and turn it slowly. ACTION Yes Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to next step. No Go to next step.
ON-BOARD DIAGNOSTIC DTC P0134 Front HO2S circuit no activity detected F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 VERIFY RELATED PENDING AND STORED Yes Go to appropriate DTC troubleshooting procedures.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT GAS LEAKAGE FROM EXHAUST SYSTEM • Visually check if any gas leakage is found between exhaust manifold and front HO2S. • Is there any gas leakage? 7 INSPECT SEALING OF ENGINE COOLANT PASSAGE Warning • Removing radiator cap when radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing radiator cap, wrap a thick cloth around and turn it slowly.
ON-BOARD DIAGNOSTIC DTC P0138 Rear HO2S circuit high input F Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded? 2 3 4 5 6 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Information availability. • Is any related Service Information available? VERIFY RELATED PENDING OR STORED DTCS • Turn ignition key to OFF, then ON (Engine OFF). • Verify pending code or stored DTCs using WDS or equivalent.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 VERIFY TROUBLESHOOTING OF DTC P0138 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from memory using WDS or equivalent. • Run PCM adaptive memory procedure drive mode and HO2S heater, HO2S, and TWC repair verification drive mode. (See F64 OBD DRIVE MODE.) • Is PENDING CODE the same as DTC present? 8 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.
ON-BOARD DIAGNOSTIC DTC P0140 Rear HO2S circuit no activity detected F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 VERIFY RELATED PENDING AND STORED Yes Go to appropriate DTC troubleshooting procedures.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT GAS LEAKAGE FROM EXHAUST SYSTEM • Visually check if any gas leakage is found between exhaust pipe and rear HO2S. • Is there any gas leakage? 7 INSPECT SEALING OF ENGINE COOLANT PASSAGE Warning • Removing radiator cap when radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing radiator cap, wrap a thick cloth around and turn it slowly.
ON-BOARD DIAGNOSTIC DTC P0171 POSSIBLE CAUSE Fuel trim system too lean • Misfire • Front HO2S deterioration • Front HO2S heater malfunction • Pressure regulator malfunction • Fuel pump malfunction • Fuel filter clogged or restricted • Fuel leakage on fuel line from fuel delivery pipe and fuel pump • Fuel return hose clogged • Leakage exhaust system • Purge solenoid valve malfunction • Purge solenoid hoses improper connection • Insufficient compression • Variable valve timing control system improper operat
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 INSPECT MAF PID • Start engine. • Access MAF PID using WDS or equivalent. • Verify that MAF PID changes quickly according to race engine RPM. • Is MAF PID response okay? 8 INSPECT FOR EXCESSIVE AIR SUCTION OF INTAKE AIR SYSTEM • Visually inspect for loosen, cracks or damages hoses on intake air system. • Is there any malfunction? 9 INSPECT FUEL LINE PRESSURE • Turn ignition key to OFF. Note • If engine wont start, inspect fuel line pressure with ignition key ON.
ON-BOARD DIAGNOSTIC STEP INSPECTION 16 INSPECT VARIABLE VALVE TIMING CONTROL SYSTEM OPERATION Note • The following test should be performed for variable valve timing control system. Go to next step for vehicles without variable valve timing control system. 17 18 19 • Inspect variable valve timing control system operation. (See F239 Variable Valve Timing Control System Operation Inspection.
ON-BOARD DIAGNOSTIC STEP INSPECTION 2 VERIFY RELATED PENDING CODE OR STORED DTCS • Turn ignition key to OFF, then ON (Engine OFF). • Verify related pending code or stored DTCs. • Is other DTCs present? 3 IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA • Is DTC P0172 on FREEZE FRAME DATA? 4 5 6 7 8 9 10 11 VERIFY CURRENT INPUT SIGNAL STATUS (IGNITION KEY TO ON/IDLE) • Access ECT, MAF, TP and VSS PIDs using WDS or equivalent.
ON-BOARD DIAGNOSTIC DTC P0300 DTC P0300 DETECTION CONDITION POSSIBLE CAUSE A6E397001085W01 Random misfire detection • PCM monitors CKP sensor input signal interval time. PCM calculates change of interval time for each cylinder. If change of interval time exceeds preprogrammed criteria, PCM detects misfire in the corresponding cylinder.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 VERIFY CURRENT INPUT SIGNAL STATUS UNDER TROUBLE CONDITION • Inspect same PIDs as in Step 4 while simulating FREEZE FRAME DATA condition. • Is there any signal which causes drastic changes? 6 INSPECT CMP SENSOR • Inspect CMP sensor. (See F55 CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) • Is CMP sensor okay? 7 8 9 10 11 12 13 14 VERIFY CKP SENSOR INSTALLATION CONDITION • Inspect for CKP sensor looseness.
ON-BOARD DIAGNOSTIC STEP INSPECTION 15 INSPECT FUEL LINE FROM FUEL PUMP TO FUEL DELIVERY PIPE • Visually inspect for fuel leakage in fuel line for any leakage. • Is any fuel leakage found? 16 17 INSPECT ENGINE COMPRESSION • Inspect engine compression. (See B9 COMPRESSION INSPECTION.) • Is it okay? INSPECT VARIABLE VALVE TIMING CONTROL SYSTEM OPERATION Note • The following test should be performed for variable valve timing control system.
ON-BOARD DIAGNOSTIC STEP INSPECTION 21 INSPECT SEALING OF ENGINE COOLANT PASSAGE Warning • Removing radiator cap when radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing radiator cap, wrap thick cloth around and turn it slowly. ACTION Yes Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to next step. No Go to next step.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded? 2 3 4 5 6 7 8 9 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Information availability. • Is any related Service Information available? VERIFY RELATED PENDING CODE OR STORED DTCS • Turn ignition key to OFF then ON (Engine OFF). • Verify related pending code or stored DTCs.
ON-BOARD DIAGNOSTIC STEP INSPECTION 10 INSPECT SEALING OF ENGINE COOLANT PASSAGE Warning • Removing radiator cap when radiator is hot is dangerous, Scalding coolant and steam may shoot out and cause serious injury. • When removing radiator cap, wrap thick cloth around and turn it slowly. ACTION Yes Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 12. No Go to next step. • Remove radiator cap.
ON-BOARD DIAGNOSTIC DTC P0327 Knock sensor circuit low input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT KNOCK SENSOR CONNECTOR Yes Repair terminal, then go to Step 8. TERMINAL No Go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT FOR SHORT CIRCUITS • Inspect continuity between knock sensor female terminals A and B (harness-side). • Is there continuity? 7 INSPECT PCM CONNECTOR TERMINAL • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection at terminals 2P and 2S (damaged, pulled-out pins, corrosion, etc.). • Is there any malfunction? 8 VERIFY TROUBLESHOOTING OF DTC P0327 COMPLETED • Make sure to reconnect all disconnected connectors.
ON-BOARD DIAGNOSTIC DTC P0328 Knock sensor circuit high input F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT KNOCK SENSOR CONNECTOR Yes Repair terminal, then go to step 6. TERMINAL No Go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 VERIFY TROUBLESHOOTING OF DTC P0328 COMPLETED • Make sure to connect all disconnected connectors. • Clear DTC from PCM memory using WDS or equivalent. • Perform KOEO/KOER self-test. (See F66 KOEO/KOER SELF-TEST.) • Is same DTC present? 7 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? ACTION Yes Replace PCM, then go to next step. (See F43 PCM REMOVAL/INSTALLATION.) No Go to next step.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded? 2 3 4 5 6 7 8 9 10 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Information availability. • Is any related Service Information available? VERIFY CKP SENSOR VOLTAGE • Disconnect CKP sensor connector. • Connect voltmeter between CKP sensor connector terminals A and B (sensor-side).
ON-BOARD DIAGNOSTIC STEP INSPECTION 11 VERIFY TROUBLESHOOTING OF DTC P0335 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from PCM memory using WDS or equivalent. • Start engine. • Access MAF PID using WDS or equivalent. ACTION Yes Replace PCM, then go to next step. (See F43 PCM REMOVAL/INSTALLATION.) No Go to next step. Note • MAF PID should indicate 2.0 g/s {0.26 lb/min.
ON-BOARD DIAGNOSTIC DTC P0340 Camshaft position (CMP) sensor circuit malfunction F Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded? 2 3 4 5 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Information availability. • Is any related Service Information available? VERIFY CMP SENSOR VOLTAGE • Disconnect CMP sensor connector. • Connect voltmeter between CMP sensor connector terminals A and B (sensor-side).
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT CMP CIRCUIT FOR SHORT TO GROUND • Inspect continuity between following terminal and body ground: CMP sensor connector terminal A (harnessside) CMP sensor connector terminal B (harnessside) • Is there any continuity? 7 INSPECT CMP CIRCUITS FOR SHORTS • Inspect continuity between CMP sensor connector terminals A and B (harness-side). • Is there any continuity? 8 INSPECT POOR CONNECTION OF PCM CONNECTOR • Disconnect PCM connector.
ON-BOARD DIAGNOSTIC DTC P0403 POSSIBLE CAUSE EGR valve (stepper motor) circuit malfunction • EGR valve malfunction • Connector or terminal malfunction • Short to power circuit in wiring between EGR valve terminal E and PCM terminal 4E • Short to power circuit in wiring between EGR valve terminal A and PCM terminal 4H • Short to power circuit in wiring between EGR valve terminal B and PCM terminal 4K • Short to power circuit in wiring between EGR valve terminal F and PCM terminal 4N • Short to ground circu
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 INSPECT POWER CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to ON (Engine OFF). • Measure voltage following terminal and body ground. EGR valve terminal C EGR valve terminal D • Is voltage B+? 4 INSPECT EGR VALVE • Perform EGR valve inspection. (See F40 EGR VALVE INSPECTION.) • Is EGR valve okay? 5 INSPECT FOR CONTROL CIRCUIT FOR SHORT TO GROUND • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC DTC P0420 DTC P0420 A6E397001086W02 Catalyst system efficiency below threshold • PCM compares number of front HO2S and rear HO2S inversions for a predetermined time. PCM monitors number of inversions rear side performs while front side inverts for a specified number of times when the following monitoring conditions are met. PCM detects inversion ratio. If inversion ratio is below threshold, PCM determins that catalyst system has deteriorated.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 VERIFY TROUBLESHOOTING OF DTC P0420 OR P0431 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from memory using WDS or equivalent. • Run PCM adaptive memory procedure drive mode and HO2S heater, HO2S, and EGR system repair verification drive mode. (See F64 OBD DRIVE MODE.) • Is PENDING CODE the same as DTC present? 8 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 CLASSIFY OPEN CIRCUIT OR SHORT TO Yes Go to Step 4. GROUND MALFUNCTION No Go to next step.
ON-BOARD DIAGNOSTIC End Of Sie DTC P0480 A6E397001086W04 DTC P0480 Fan relay control circuit malfunction • PCM monitors cooling fan relay No.2 control signal at PCM terminal 4L. if PCM detects cooling fan relay DETECTION No.2 control signal does not change coolant temperature above 100 °C {212 °F}, PCM determines that CONDITION cooling fan relay No.2 control has malfunction. • cooling fan relay No.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 INSPECT COOLING FAN RELAY NO.2 POWER CIRCUIT FOR OPEN • Turn ignition switch to ON (Engine OFF). • Measure voltage between cooling fan relay No.2 terminal E (harness side) and body ground. • Is voltage B+? 4 INSPECT COOLING FAN RELAY NO.2 • Inspect cooling fan relay No.2. (See T24 RELAY INSPECTION) • Is cooling fan relay No.2 okay? 5 INSPECT COOLING FAN RELAY NO.2 CONTROL CIRCUIT FOR SHORT TO POWER • Measure voltage between cooling fan relay No.
ON-BOARD DIAGNOSTIC DTC P0500 DTC P0500 DETECTION CONDITION POSSIBLE CAUSE A6E397001087W01 Vehicle speed sensor (VSS) circuit malfunction (MTX vehicles without ABS) • Vehicle speed signal does not input after following conditions are met: Gear is in other than neutral position Load is above 40% Engine speed is 2,000 rpm or above Diagnostic support note: • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 VERIFY CURRENT INPUT SIGNAL STATUS-IS CONCERN INTERMITTENT OR CONSTANT • Connect WDS or equivalent to DLC-2. • Start engine. • Access VSS PID using WDS or equivalent. Vehicle speed 20 km/h {12.4 mph}: 20km/ h {12.4 mph} Vehicle speed 40 km/h {24.8 mph}: 40km/ h {24.8 mph} • Are PID readings within specification? 4 INSPECT POOR CONNECTION OF VSS CONNECTOR • Verify that the VSS connector is connected securely.
ON-BOARD DIAGNOSTIC STEP INSPECTION 11 VERIFY TROUBLESHOOTING OF DTC P0500 COMPLETED • Make sure to reconnect all disconnected connectors. • Turn ignition key to ON (Engine OFF). • Clear DTC from PCM memory using WDS or equivalent. • Warm up engine. • Access RPM and LOAD PID using WDS or equivalent. • Drive vehicle under following conditions for 18s.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT GENERATOR CONTROL CIRCUIT MALFUNCTION • Apply electrical load. • Is engine speed increased? 6 INSPECT AIR CLEANER ELEMENT • remove air cleaner element with engine running. • Is engine speed increased? 7 INSPECT THROTTLE BODY PASSAGE • Is throttle body clogged? 8 9 10 INSPECT ENGINE COMPRESSION • Inspect engine compression. (See B9 COMPRESSION INSPECTION.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 VERIFY RELATED PENDING OR STORED DTCS • Turn ignition key to OFF, then ON (Engine OFF). • Verify pending code or stored DTCs using WDS or equivalent. • Is other DTC present? 4 INSPECT IAC VALVE MALFUNCTION • Perform IAC valve inspection. (See F13 IDLE AIR CONTROL (IAC) VALVE INSPECTION.) • Is IAC valve okay? 5 INSPECT A/C MAGNET CLUTCH OPERATION • Turn blower motor switch off.
ON-BOARD DIAGNOSTIC DTC P0507 DTC P0507 A6E397001087W04 Idle control system RPM higher than expected • Actual idle speed is higher than expected by 200 rpm for 14 s, when brake pedal is depressed (brake switch is on) and steering wheel is held straight ahead (power steering pressure switch is off). Note • If atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or intake air temperature is below -10 °C {14 °F}, PCM cancels diagnosis of P0507.
ON-BOARD DIAGNOSTIC STEP INSPECTION 9 VERIFY TROUBLESHOOTING OF DTC P0507 COMPLETED • Make sure to reconnect all disconnected connectors. • Start engine. • Clear DTC from PCM memory using WDS or equivalent. • Depress brake pedal for 14 s or more. • Is PENDING CODE the same as DTC present? 10 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Sie DTC Of P0511 DTC P0511 ACTION Yes Replace PCM, then go to next step.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF IAC VALVE Yes Repair or replace terminal, then go to Step 8. CONNECTOR No Go to next step. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC DTC P0550 DTC P0550 DETECTION CONDITION POSSIBLE CAUSE A6E397001087W06 PSP switch circuit malfunction • PCM monitors PSP switch signal at PCM terminal 1Z. If input voltage is low (switch stays on) for 1 minute when VSS is above 60 km/h {37.3 mph} and ECT is above 60 °C {140 °F}, PCM determines that PSP switch circuit has malfunction. Diagnostic support note • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT PSP SWITCH • Perform PSP switch inspection. (See F58 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION.) • Is PSP switch okay? 5 INSPECT PSP SWITCH SIGNAL CIRCUIT FOR SHORT TO GROUND • Disconnect PCM connector. • Inspect continuity between PSP switch terminal (harness-side) and body ground. • Is there any continuity? 6 INSPECT POOR CONNECTION OF PCM CONNECTOR • Turn ignition key to OFF • Disconnect PCM connector.
ON-BOARD DIAGNOSTIC DTC P0602 DTC P0602 DETECTION CONDITION POSSIBLE CAUSE A6E397001088W01 PCM programming error • No configuration data in PCM Note • If PCM CONFIGURATION is successful, the PCM stored DTC P0602 and illuminates the MIL (System i s normal) Clear the DTC P0602 using WDS or equivalent after PCM CONFIGURATION. • MIL goes off after three drive cycles with no failure (DTCs remain in PCM). • Complete configuration has not been completed.
ON-BOARD DIAGNOSTIC End Of Sie DTC P0661 A6E397001088W03 DTC P0661 Variable intake-air system (VIS) contol solenoid valve circuit low input • PCM monitors VIS control solenoid valve control signal at PCM terminal 4R. If PCM turns VIS control DETECTION solenoid valve off but voltage at PCM terminal 4R still remains low, PCM determines that VIS control CONDITION solenoid valve circuit has malfunction.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT VIS CONTROL SOLENOID VALVE CONTROL CIRCUIT FOR SHORT TO GROUND • Inspect continuity between VIS control solenoid valve terminal A (harness-side) and body ground. • Is there continuity? 6 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Disconnect PCM connector. • Inspect for poor connection at terminal 4R. (damaged/pulled-out pins, corrosion, etc.).
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT VIS CONTROL SOLENOID VALVE Yes Repair or replace terminal, then go to Step 6. CONNECTOR FOR POOR CONNECTION No Go to next step.
ON-BOARD DIAGNOSTIC DTC P0703 DTC P0703 DETECTION CONDITION POSSIBLE CAUSE A6E397001089W01 Brake switch input malfunction • PCM monitors changes in input voltage from brake switch. If PCM does not detect PCM terminal 1K voltage changes while alternately accelerating and decelerating 8 times, PCM determines that neutral switch circuit has malfunction. Diagnostic support note • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT BRAKE SWITCH CONNECTOR FOR POOR CONNECTION • Turn ignition switch to OFF. • Disconnect brake switch connector. • Inspect for poor connection (damaged/pulledout terminals, corrosion, etc.). • Is there malfunction? 5 CLASSIFY BRAKE SWITCH OR CIRCUIT • Connect WDS or equivalent to DLC-2. • Access BOO PID. • Connect a jumper wire between brake switch terminal A and B. • Is BOO PID on? 6 INSPECT BRAKE SWITCH • Perform brake switch inspection.
ON-BOARD DIAGNOSTIC STEP INSPECTION 14 VERIFY TROUBLESHOOTING OF DTC P0703 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory using WDS or equivalent. • Drive vehicle 30 km/h {18.6 mph} or more. • Depress and release brake pedal more than 8 times while driving vehicle. • Is PENDING CODE the same as DTC present? 15 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded? 2 3 4 5 6 7 8 9 10 11 12 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service information availability. • Is any related Service information available? CLASSIFY HIGH INPUT OR LOW INPUT • Connect WDS or equivalent to DLC-2. • Access CPP PID. • Verify CPP PID during clutch pedal operation. • Is CPP PID always OFF?.
ON-BOARD DIAGNOSTIC STEP INSPECTION 13 INSPECT CLUTCH SWITCH SIGNAL CIRCUIT FOR SHORT TO GROUND • Inspect continuity between clutch switch terminal B and ground. • Is there any continuity? 14 VERIFY TROUBLESHOOTING OF DTC P0704 COMPLETED • Make sure to reconnect all disconnected connectors. • Start engine. • Clear DTC from PCM memory using WDS or equivalent. • Operate clurch pedal during drive vehicle below 30 km/h {19 mph} 8 times altemetely.
ON-BOARD DIAGNOSTIC DTC P0850 Neutral switch circuit malfunction F Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME DATA been recorded? 2 3 4 5 6 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Information availability. • Is any related Service Information available? CLASSIFY HIGH INPUT OR LOW INPUT • Connect WDS or equivalent to DLC-2. • Access CPP/PNP PID. • Verify CPP/PNP PID when gear is neutral position.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 INSPECT NEUTRAL SWITCH GROUND CIRCUIT FOR OPEN CIRCUIT • Inspect continuity between neutral switch terminal A and ground. • Is there any continuity? 8 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Turn ignition switch to OFF. • Disconnect PCM connector. • Inspect for poor connection (damaged/pulledout terminals, corrosion, etc.).
ON-BOARD DIAGNOSTIC DTC P1410 POSSIBLE CAUSE Variable air duct (VAD) control system circuit malfunction • VAD solenoid valve malfunction. • Connector or terminal malfunction.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 INSPECT POOR CONNECTION OF PCM CONNECTOR • Disconnect PCM connector. • Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.). • Are there any malfunctions? 8 INSPECT CONTROL CIRCUIT FOR SHORT TO GROUND • Disconnect battery cables. • Inspect continuity between VAD solenoid valve terminal B and body ground.
ON-BOARD DIAGNOSTIC DTC P1562 PCM +BB (back-up battery) voltage low F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT EEC FUSE Yes Go to step 5. • Turn ignition key to OFF.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? ACTION Yes Go to applicable DTC troubleshooting. (See F67 DTC TABLE.) No Troubleshooting completed. End Sie DTC Of P2006 DTC P2006 A6E397001083W03 Variable tumble control system (VTCS) shutter valve stuck closed • PCM monitors mass air amount.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 CLASSIFY INTERMITTENT CONCERN OR CONTINUOUS CONCERN • Clear DTC from PCM memory using WDS or equipment. • Drive vehicle under following conditions: Engine coolant temperature is above 63 °C {145 °F}.
ON-BOARD DIAGNOSTIC DTC P2009 DTC P2009 DETECTION CONDITION POSSIBLE CAUSE A6E397001083W04 Variable tumble control solenoid valve circuit low input • PCM monitors variable tumble control solenoid valve control signal at PCM terminal 4T. If PCM turns variable tumble control solenoid valve off but voltage at PCM terminal 4T still remains low, PCM determines that VTCS solenoid valve circuit has malfunction. Diagnostic support note • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT VARIABLE TUMBLE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Disconnect variable tumble control solenoid valve connector. • Turn ignition key to ON (Engine OFF). • Measure voltage between variable tumble control solenoid valve terminal A (harnessside) and body ground. • Is voltage B+? 5 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection at PCM terminal 4T.
ON-BOARD DIAGNOSTIC DTC P2010 DTC P2010 DETECTION CONDITION POSSIBLE CAUSE A6E397001083W05 Variable tumble control solenoid valve circuit high input • PCM monitors variable tumble control solenoid valve control signal at PCM terminal 4T. If PCM turns variable tumble control solenoid valve on but voltage at PCM terminal 4T still remains high, PCM determines that variable tumble control solenoid valve circuit has malfunction. Diagnostic support note • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection at PCM terminal 4T. (damaged/pulled-out pins, corrosion, etc.). • Is there malfunction? 5 INSPECT VARIABLE TUMBLE CONTROL SOLENOID VALVE CONTROL CIRCUIT FOR SHORT TO POWER • Remove variable tumble control solenoid valve. • Turn ignition key to ON (Engine OFF). • Measure voltage between PCM terminal 4T and body ground.
ON-BOARD DIAGNOSTIC DTC P2228 DTC P2228 DETECTION CONDITION POSSIBLE CAUSE A6E397001083W06 BARO sensor circuit low input • PCM monitors input voltage from BARO sensor. If input voltage at PCM terminal 1G is below 0.35 V, PCM determines that BARO sensor circuit has malfunction. Diagnostic support note • • • • • • • • • • This is a continuous monitor (CCM). MIL illuminates if PCM detects the above malfunction condition during first drive cycle.
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT BARO SENSOR MALFUNCTiON • Perform BARO sensor inspection. (See F60 BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION.) • Is BARO sensor okay? 5 INSPECT POWER SUPPLY CIRCUIT VOLTAGE AT BARO SENSOR CONNECTOR Note • If DTCs P0107 and P0122 are also retrieved with P2228, go to REFERENCE VOLTAGE troubleshooting procedure. 6 7 8 9 • Measure voltage between BARO sensor terminal C (harness-side) and body ground. • Is voltage within 4.55.
ON-BOARD DIAGNOSTIC DTC P2229 DTC P2229 DETECTION CONDITION POSSIBLE CAUSE A6E397001083W07 BARO sensor circuit high input • PCM monitors input voltage from BARO sensor. If input voltage at PCM terminal 1G is above 4.92 V, PCM determines that BARO sensor circuit has malfunction. Diagnostic support note • • • • • • • • • • • This is a continuous monitor (CCM). MIL illuminates if PCM detects the above malfunction condition during first drive cycle.
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT BARO SENSOR MALFUNCTiON • Perform BARO sensor inspection. (See F60 BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION.) • Is BARO sensor okay? 5 VERIFY BARO SENSOR SIGNAL CIRCUIT FOR SHORT TO REFERENCE VOLTAGE CIRCUIT • Measure voltage between BARO sensor terminal A and body ground. • Is voltage above 4.92 V? 6 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Disconnect PCM connector. • Inspect for poor connection at terminal 2H (damaged/pulled-out pins, corrosion, etc.).
ON-BOARD DIAGNOSTIC DTC P2502 A6E397001083W08 DTC P2502 Generator terminal B circuit open DETECTION • PCM judges generator output voltage is above 17 V or battery voltage is below 11 V during engine CONDITION running. • Open circuit between generator terminal B and battery positive terminal • Battery malfunction POSSIBLE • Generator malfunction CAUSE • PCM is poorly connected. • PCM, generator and/or battery are poorly connected.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 VERIFY TROUBLESHOOTING OF DTC P2502 COMPLETED • Make sure to reconnect all connectors. • Clear DTC from memory using WDS or equivalent. • Perform KOER self-test. (See F66 KOEO/KOER SELF-TEST.) • Is same DTC present? 7 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Of Sie DTC P2503 ACTION Yes Replace PCM, then go to next step. (See F43 PCM REMOVAL/INSTALLATION.) No Go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 INSPECT POOR CONNECTION OF PCM CONNECTOR • Turn ignition key to OFF. • Disconnect PCM connector. • Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.). • Is there a malfunction? 4 INSPECT POOR CONNECTION OF GENERATOR CONNECTOR • Disconnect generator connector. • Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.).
ON-BOARD DIAGNOSTIC DTC P2504 Battery overcharge F Diagnostic procedure STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform DTC CONFIRMATION PROCEDURE. No Intermittent concern exists. Go to INTERMITTENT (See F66 DTC CONFIRMATION CONCERN TROUBLESHOOTING procedure. PROCEDURE.) (See F227 INTERMITTENT CONCERN • Is same DTC present? TROUBLESHOOTING.) 2 INSPECT POOR CONNECTION OF Yes Repair or replace terminals, then go to Step 7. GENERATOR CONNECTOR No Go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT GENERATOR CONTROL TERMINAL FOR SHORT TO POWER • Measure resistance between generator terminal D (part-side) and body ground. • Is voltage B+? 7 VERIFY TROUBLESHOOTING OF DTC P2504 COMPLETED • Make sure to reconnect all connectors. • Clear DTC from PCM memory using WDS or equivalent. • Perform KOER self-test. (See F66 KOEO/KOER SELF-TEST.) • Is same DTC present? 8 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See F66 AFTER REPAIR PROCEDURE.
TROUBLESHOOTING TROUBLESHOOTING ENGINE SYMPTOM TROUBLESHOOTING A6E398018881W01 • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. Diagnostic Index No. 1 2 3 5 6 7 TROUBLESHOOTING ITEM Melting of main or other fuses MIL illuminates Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls.
TROUBLESHOOTING QUICK DIAGNOSTIC CHART A6E398018881W02 A6E3980W001 F182
TROUBLESHOOTING F A6E3980W002 F183
TROUBLESHOOTING A6E3980W003 F184
TROUBLESHOOTING F A6E3980W004 End Of Sie F185
TROUBLESHOOTING NO.1 MELTING OF MAIN OR OTHER FUSES A6E398018881W03 1 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse.
TROUBLESHOOTING Diagnostic procedure STEP INSPECTION 1 Connect WDS or equivalent to DLC-2. Retrieve any DTC. Are there DTC displayed? 2 RESULTS ACTION Yes DTC is displayed: • Go to appropriate DTC test. No No DTC is displayed: • Inspect instrument cluster operation. See Section T. Verify test results. • If okay, return to diagnostic index to service any additional symptoms. • If malfunction remains, replace PCM. End SieNOT CRANK NO.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 9 Is there continuity between PCM terminal 4I and Yes Go to next step. starter relay with clutch pedal depressed (MTX No Repair replace wiring harness. with starter interlock system), P or N position (ATX)? 10 Inspect following: Yes Go to next step. • Battery connection No Service as necessary. • Battery condition Repeat Step 10. • Transaxle is in Park or Neutral. (ATX) • Clutch is fully depressed.
TROUBLESHOOTING NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK A6E398018881W06 4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK • Starter cranks engine at normal speed but engine requires excessive cranking time before starting. DESCRIPTION • Battery is in normal condition.
TROUBLESHOOTING STEP INSPECTION 6 Visually inspect CKP sensor and teeth of crankshaft pulley. Are CKP sensor and teeth of crankshaft pulley okay? 7 Measure gap between CKP sensor and teeth of crankshaft pulley. Specification 0.51.9 mm {0.0200.75 in} Is gap within specification? 8 Remove and shake PCV valve. Does PCV valve rattle? 9 10 11 12 Install fuel pressure gauge between fuel pipe and fuel distributor. Connect a jumper wire between F/P terminal at DLC-2 in engine compartment and GND.
TROUBLESHOOTING NO.5 ENGINE STALLS-AFTER START/AT IDLE A6E398018881W07 5 DESCRIPTION ENGINE STALLSAFTER START/AT IDLE • Engine stops unexpectedly.
TROUBLESHOOTING STEP INSPECTION 4 Does security light illuminate? 5 Connect WDS or equivalent to DLC-2 and retrieve DTC. Are any of following DTCs displayed? RESULTS Yes No Yes No ACTION Go to next step. Inspect instrument cluster and wiring harness. Go to appropriate DTC test. Go to next step. DTC 6 7 8 B1213, B1342, B1600, B1602, B1681, B2103, B2431 Is there continuity between PCM GND terminals 4X, 2AB, 2AC and GND? Measure voltage between PCM GND terminals 4X, 2AB, 2AC and coil terminal C.
TROUBLESHOOTING STEP INSPECTION 14 Connect WDS or equivalent to DLC-2. Access RPM PID. Is RPM PID indicating engine speed during engine cranking? 15 16 Visually inspect CKP sensor and teeth of crankshaft pulley. Are CKP sensor and teeth of crankshaft pulley okay? Measure gap between CKP sensor and teeth of crankshaft pulley. Specification 17 18 0.51.9 mm {0.0200.075 in} Is gap within specification? Inspect for cracks on high-tension leads.
TROUBLESHOOTING STEP 24 25 26 27 28 29 30 INSPECTION Note • Following test is for stall concerns with A/ C on. If other symptoms exist, go to next step. Connect pressure gauges to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressures. Are pressures within specifications? (See U12 REFRIGERANT PRESSURE CHECK.) Disconnect vacuum hose between purge solenoid valve and intake manifold from purge solenoid side. Plug opening end of vacuum hose. Start engine.
TROUBLESHOOTING NO.6 CRANKS NORMALLY BUT WILL NOT START A6E398018881W08 6 CRANKS NORMALLY BUT WILL NOT START • Starter cranks engine at normal speed but engine will not run. • Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after engine stall. DESCRIPTION • Fuel is in tank. • Battery is in normal condition.
TROUBLESHOOTING STEP INSPECTION 3 Is coil connector securely connected to coil? 4 Does security light illuminate? 5 Connect WDS equivalent to DLC-2 and retrieve DTC. Are any of following DTCs displayed? RESULTS ACTION Yes Go to next step. No Connect coil connector securely. Return to Step 2. Yes Go to next step. No Inspect instrument cluster and wiring harness. Yes Go to appropriate DTC test. No Go to next step.
TROUBLESHOOTING STEP INSPECTION 14 Will engine start and run smoothly at part throttle? 15 Connect WDS or equivalent to DLC-2. Access RPM PID. Is RPM PID indicating engine speed when cranking engine? 16 Visually inspect CKP sensor and teeth of crankshaft pulley. Are CKP sensor and teeth of crankshaft pulley okay? Measure gap between CKP sensor and teeth of crankshaft pulley. 17 Specification 18 0.51.9 mm {0.0200.075 in} Is gap within specification? Inspect for cranks on high-tension leads.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 26 Is air leakage felt or heard at intake-air system Yes Repair or replace. components while racing engine to higher No Go to next step. speed? 27 Inspect engine condition while tapping EGR Yes Replace EGR valve. valve housing. No Go to next step. Is engine condition improved? 28 Note Yes Go to next step. • The following test should be performed for No Repair or replace malfunctioning parts. vehicles with variable valve timing control system.
TROUBLESHOOTING NO.8 ENGINE RUNS ROUGH/ROLLING IDLE A6E398018881W10 8 ENGINE RUNS ROUGH/ROLLING IDLE • Engine speed fluctuates between specified idle speed and lower speed and engine shakes DESCRIPTION excessively. • Idle speed is too slow and engine shakes excessively.
TROUBLESHOOTING STEP INSPECTION 2 Connect WDS or equivalent to DLC-2. Retrieve any continuous memory, KOEO and KOER. Are there any DTCs displayed? 3 4 5 6 7 RESULTS ACTION Yes DTC is displayed: Go to appropriate DTC test. No No DTC is displayed: Go to next step. Is engine overheating? Yes Go to symptom troubleshooting "No.17 Cooling system concerns - Overheating". No Go to next step. Note Yes Go to next step.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 13 Connect WDS or equivalent to DLC-2. Yes Go to next step. Start the engine and run it at idle. No Inspect and repair or replace faulty HO2S, harness, Access O2S11 PID. connector or terminal, then go to next step. Is O2S11 PID okay? • More than 0.45 V when accelerator pedal is suddenly depressed: rich condition • Less than 0.
TROUBLESHOOTING STEP INSPECTION 2 Connect WDS or equivalent to DLC-2. Retrieve any continuous memory DTCs. Are there any DTCs displayed? 3 4 5 RESULTS ACTION Yes DTC is displayed: Go to appropriate DTC test. No No DTC is displayed: Go to next step. Connect WDS or equivalent to DLC-2. Yes Go to next step. Access ACSW, COLP, CPP, CPP/PNP, TR and No ACSW PID: Inspect A/C switch, refrigerant pressure PSP PIDs. switch and fan switch. Monitor each PID.
TROUBLESHOOTING STEP INSPECTION 6 Disconnect vacuum hose between purge solenoid valve and intake manifold from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? 7 Connect WDS or equivalent to DLC-2. Access TP, MAF, VSS, BOO, CPP, CPP/PNP and TR PIDs. Monitor each PID while driving vehicle. (See F45 PCM INSPECTION.) Are PIDs okay? 8 RESULTS ACTION Yes Inspect evaporative emission control system. No Go to next step.
TROUBLESHOOTING NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES A6E398018881W13 ENGINE STALLS/QUITS ACCELERATION/CRUISE ENGINE RUNS ROUGH ACCELERATION/CRUISE MISSES ACCELERATION/CRUISE 11 BUCK/JERK ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE ACCELERATION SURGES ACCELERATION/CRUISE • Engine stops unexpectedly at beginning of acceleration or during acceleration. • Engine stops unexpectedly while cruising.
TROUBLESHOOTING Diagnostic procedure STEP INSPECTION 1 Verify for following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold: such as EGR valve, IAC valve • Ignition wiring • Fuel quality (e.g.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 11 Install fuel pressure gauge between fuel pipe Yes Go to next step. and fuel distributor. No Zero or low: Connect jumper wire between F/P terminal at Inspect for clogged fuel line. DLC-2 in engine compartment and GND. If okay, replace fuel pump unit. Turn ignition switch to ON position. High: Is fuel line pressure correct with ignition switch Replace fuel pump unit.
TROUBLESHOOTING NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE A6E398018881W14 12 DESCRIPTION LACK/LOSS OF POWER ACCELERATION/CRUISE Performance is poor under load (e.g., power down when climbing hills).
TROUBLESHOOTING STEP INSPECTION 2 Connect WDS or equivalent to DLC-2. Retrieve any continuous memory, KOEO and KOER DTCs. If engine stall condition exists, retrieve continuous memory and KOEO DTCs. Are there any DTCs displayed? 3 Is engine overheating? 4 Connect WDS or equivalent to DLC-2. Access RPM, MAF, TP and VSS PIDs. Drive vehicle while monitoring PIDs. Are PIDs within specifications? (See F45 PCM INSPECTION.) 5 Visually inspect CKP sensor and teeth of crankshaft pulley.
TROUBLESHOOTING STEP 13 14 15 16 17 18 19 20 INSPECTION RESULTS ACTION Note Yes Go to next step. • Following test is for engine stalling with A/ No If A/C is always on, go to symptom troubleshooting C on concern. If other symptoms exist, go "No.24 A/C is always on or A/C compressor runs to next step. continuously". For other symptoms, inspect following: Connect pressure gauge to A/C low and high • Refrigerant charging amount side pressure lines.
TROUBLESHOOTING NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE 13 DESCRIPTION POSSIBLE CAUSE A6E398018881W15 KNOCKING/PINGING - ACCELERATION/CRUISE Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g., hot spot in combustion chamber).
TROUBLESHOOTING NO.14 POOR FUEL ECONOMY A6E398018881W16 14 DESCRIPTION POOR FUEL ECONOMY Fuel economy is unsatisfactory.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 4 Is strong blue spark visible at each disconnected Yes Inspect for following: high-tension lead while cranking engine? • Spark plugs malfunction • CMP sensor is improperly installed. • Trigger wheel damage on camshaft • Open or short circuit on CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2J or 2M Repair or replace malfunctioning parts. If okay, go to next step.
TROUBLESHOOTING NO.15 EMISSION COMPLIANCE A6E398018881W17 15 DESCRIPTION EMISSION COMPLIANCE Fails emissions test.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 5 Is strong blue spark visible at each disconnected Yes Inspect for following: high-tension lead while cranking engine? • Spark plugs malfunction • Improperly installed CMP sensor • Damage of trigger wheel on camshaft • Open or short circuit on CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2J or 2M Repair or replace malfunctioning parts. If okay, go to next step.
TROUBLESHOOTING NO.17 COOLING SYSTEM CONCERNS-OVERHEATING A6E398018881W19 17 DESCRIPTION COOLING SYSTEM CONCERNS -OVERHEATING Engine runs at higher than normal temperature/overheats. • Improper coolant level • Blown fuses • Coolant leakage • Excessive A/C system pressure • A/C system operation is improper • Improper water/anti-freeze mixture • Fans reverse rotation • Poor radiator condition POSSIBLE CAUSE • Thermostat malfunction • Radiator hoses damage • Condenser fan is inoperative.
TROUBLESHOOTING STEP INSPECTION 9 Cool down the engine. Remove thermostat and inspect operation. (See E7 THERMOSTAT REMOVAL/ INSTALLATION.) (See E8 THERMOSTAT INSPECTION.) Is thermostat okay? 10 RESULTS ACTION Yes Engine coolant temperature and thermostat are okay, inspect engine block for leakage or blockage. No Access ECT PID. Inspect for both ECT PID and temperature gauge readings.
TROUBLESHOOTING NO.19 EXHAUST SMOKE 19 DESCRIPTION POSSIBLE CAUSE A6E398018881W21 EXHAUST SMOKE Blue, black, or white smoke from exhaust system Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system malfunction (coolant loss) • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted. • Fuel return line is restricted.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 6 Install fuel pressure gauge between fuel pipe Yes Go to next step. and fuel distributor. No Zero or low: Start engine and run it at idle. • Inspect for clogged fuel line. Measure fuel line pressure at idle. • If okay, replace fuel pump unit. Is fuel line pressure correct at idle? High: (See F20 FUEL LINE PRESSURE • Replace fuel pump unit. INSPECTION) 7 Is strong blue spark visible at each disconnected Yes Inspect spark plugs and CMP sensor.
TROUBLESHOOTING STEP INSPECTION 4 Connect WDS or equivalent to DLC-2. Retrieve any continuous memory, KOEO and KOER DTCs. Are there any DTCs displayed? 5 RESULTS ACTION Yes DTC is displayed: Go to appropriate DTC test. No No DTC is displayed: Inspect charcoal canister for fuel saturation. If excess amount of liquid fuel is present, replace charcoal canister. Verify test results. • If okay, return to diagnostic index to service any additional symptoms. • If malfunction remains, replace PCM.
TROUBLESHOOTING NO.
TROUBLESHOOTING End OfA/C SieIS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY NO.24 A6E398018881W26 24 DESCRIPTION A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY. A/C compressor magnetic clutch does not disengage. • Stuck engagement A/C compressor magnetic clutch • A/C relay is stuck closed.
TROUBLESHOOTING STEP INSPECTION 2 Connect WDS or equivalent to DLC-2. Retrieve any continuous memory, KOEO and KOER DTCs. Are there any DTCs displayed? 3 RESULTS ACTION Yes DTC is displayed: Go to appropriate DTC test. No No DTC is displayed: Inspect TP sensor for proper adjustment. Verify test results. • If okay, return to diagnostic index to service any additional symptoms. • If malfunction remains, replace PCM. End OfEXHAUST Sie NO.
TROUBLESHOOTING End OfCONSTANT Sie NO.27 VOLTAGE 27 DESCRIPTION POSSIBLE CAUSE A6E398018881W29 CONSTANT VOLTAGE Incorrect constant voltage • Constant voltage circuit malfunction Note • TP sensor uses constant voltage. Diagnostic procedure STEP INSPECTION RESULTS ACTION 1 Disconnect TP sensor connector where constant Yes Go to Step 13. voltage circuit inspection failed. No Go to next step. Turn ignition switch to ON position.
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 9 Are DTCs present for two or more sensors Yes Go to next step. connected to PCM terminal 2H? No Repair open GND circuit to sensor where constant Sensor connected to PCM terminal 2H: voltage circuit inspection failed.
TROUBLESHOOTING NO.28 SPARK PLUG CONDITION 28 DESCRIPTION A6E398018881W30 SPARK PLUG CONDITION Incorrect spark plug condition Note • Inspecting spark plugs condition can determine whether problem is related to a specific cylinder possibly all cylinders.
TROUBLESHOOTING STEP INSPECTION 6 Carry out fuel line pressure inspection. Is fuel line pressure correct? 7 8 9 Inspect spark plug for following. • Heat range • Air gap Is spark plug okay? Remove suspected fuel injector. Inspect following: • Resistance (See F31 FUEL INJECTOR INSPECTION.) • Fuel injection volume (See F31 FUEL INJECTOR INSPECTION.) Are all above items okay? Is air cleaner element free of restrictions? 10 Carry out spark test.
TROUBLESHOOTING End Of Sie INTERMITTENT CONCERN TROUBLESHOOTING A6E398018881W31 Vibration Method 1. If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below. Note • There are several reasons vehicle or engine vibration could cause an electrical malfunction. Some of the things to check for are: Connectors not fully seated. Wire harnesses not having full play. Wires laying across brackets or moving parts.
TROUBLESHOOTING Inspection Method for Sensors 1. Connect WDS or equivalent to DLC-2. 2. Turn ignition switch to ON position (Engine OFF). Note • If engine starts and runs, perform the following steps at idle. 3. Access PIDs for the switch you are inspecting. 4. Vibrate the sensor slightly with your finger. • If PID value is unstable or malfunction occurs, check for poor connection and/or poorly mounted sensor. Inspection Method for Actuators or Relays 1. Connect WDS or equivalent to DLC-2. 2.
TROUBLESHOOTING ENGINE CONTROL SYSTEM OPERATION INSPECTION Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch is turned to ON position and off. • If there is no operation sound, inspect the following. Main relay (See T24 RELAY INSPECTION.) Harness and connector between ignition switch and main relay terminal A. Harness and connector between PCM terminal 2X and main relay terminal E. A6E398018881W32 Intake Manifold Vacuum Inspection 1.
TROUBLESHOOTING 7. Verify that the engine speed is within the specification under each load condition. • If not as specified specific load condition, inspect the following. A/C switch and related harness (See U47 CLIMATE CONTROL UNIT INSPECTION.) Fan switch and related harness (See U47 CLIMATE CONTROL UNIT INSPECTION.) PSP switch and related harness (See F58 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION.
TROUBLESHOOTING Variable Tumble Control System (VTCS) Operation Inspection 1. Connect the WDS or equivalent to the DLC-2. 2. Access ECT PID. 3. Verify that ECT PID is between 63°°C {145°° F} and 67°°C {152°° F}. 4. Start the engine. 5. Inspect rod operation under the following condition. Rod operation Engine speed Shutter valve actuator 3,750 rpm Below Above Operate Not operate • If the rod operation is not specified, inspect as follows. (1) Verify that DTC No. P2009 or P2010 is not displayed.
TROUBLESHOOTING Fuel Pump Operation Inspection 1. Connect WDS or equivalent to the DLC-2. 2. Remove the fuel-filler cap. 3. Turn the ignition switch to ON position. 4. Turn the fuel pump relay from off to on using the FP PID and inspect if the operation sound is heard. • If no operation sounds is heard, proceed to next step. 5. Measure the voltage at harness side fuel pump connector terminal B. Specification B+ (Ignition switch is on) • If the voltage is as specified, inspect the following.
TROUBLESHOOTING STEP INSPECTION 7 Are following item okay? • CKP sensor and crankshaft pulley • PCM terminal 1A/1B voltage Specification Approx. 1.5 V RESULTS ACTION Yes Inspect for open or short in wiring harness and connector of CKP sensor. No Repair or replace malfunctioning parts, then go to Step 1. EGR Control System Inspection 1. Verify that EGR valve operation (initial operation) sound is heard when the ignition switch is turned to ON position.
TROUBLESHOOTING A/C Cut-off Control System Inspection 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch actuates. • If it does not actuate, go to symptom troubleshooting No.23 A/C does not work sufficiently. 4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 25 seconds. • If it actuates, inspect as follows. (1) Connect WDS or equivalent to the DLC-2. (2) Turn the A/C switch off.
TROUBLESHOOTING 4. Inspect if the operation sound is heard from the cooling fan relay. • If the operation sound is heard, inspect the wiring harness, connectors and cooling fan motor. • If the operation sound is not heard, inspect cooling fan relay and open circuit wiring harness and connectors. 8. Turn the A/C switch and fan switch on. 9. Verify that cooling fan is operating. • If fan does not operate, inspect A/C system. Cooling fan relay No.2 1. Verify that A/C switch and fan switch are off. 2.
TROUBLESHOOTING 6. 7. 8. 9. 10. 11. 12. • If the cooling fan is not operating and condenser fan is operating, inspect for following: Short to GND circuit between PCM terminal 4F and transfer relay Transfer relay stuck ON position Short to GND circuit between PCM terminal 4B and cooling fan relay No.3 Condenser fan relay stuck ON Start the engine. Verify that the cooling fan and condenser fan are operating low speed when ECT PID is above 100°°C {212°°F}.
TROUBLESHOOTING L8, LF (Intensely hot area) engine models Cooling fan system operation (at idle) Engine condition Engine coolant temperature below 100°C {212°F} Engine coolant temperature above 100°C {212°F} (until below 97°C {208°F}) Engine coolant temperature above 108°C {233°F} (until below 105°C {208°F}) Refrigerant pressure switch (middle A/C and fan pressure) is off. switches are Refrigerant pressure on. switch (middle pressure) is on. ECT sensor malfunction 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
TROUBLESHOOTING 3. Inspect the operation sound is heard from cooling fan relay No.1 and cooling fan relay No.4. If the operation sound is not heard from cooling fan relay No.4, inspect cooling fan relay No.4 and open circuit between PCM 4F and cooling fan relay No.4 wiring harnesses and connectors. If the operation sound is not heard from cooling fan relay No.1, inspect cooling fan relay No.1 and between PCM terminal 4F and cooling fan relay No.1 wiring harnesses and connector.
TROUBLESHOOTING Variable Valve Timing Control System Operation Inspection When idling cannot be continued 1. Remove the oil control valve (OCV) and verify that the spool valve is at maximum retard position. 2. If the spool valve is stuck in advance direction, replace the oil control valve (OCV). 3. Connect the oil control valve (OCV). 4. Turn the ignition switch on. 5. Verify that the spool valve is at maximum retard position. 6. If the spool valve is stuck in advance direction, inspect for the following.
ENGINE ELECTRICAL SYSTEM G LOCATION INDEX ................................................ G-2 LOCATION INDEX............................................. G-2 CHARGING SYSTEM ............................................ G-3 BATTERY REMOVAL/INSTALLATION .............. G-3 BATTERY INSPECTION..................................... G-4 BATTERY RECHARGING .................................. G-5 GENERATOR REMOVAL/INSTALLATION ........ G-6 GENERATOR INSPECTION .............................. G-7 IGNITION SYSTEM ....
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E470001002W01 AME4700W001 .
CHARGING SYSTEM CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
CHARGING SYSTEM BATTERY INSPECTION Battery 1. Inspect the battery in the following procedure. Step Inspection Result More than 12.4 V Less than 12.4 V More than 12.4 V Less than 12.4 V 1 Measure open circuit voltage of battery. 2 Quick charge for 30 min. and recheck voltage. 3 Apply load current (see load Yes test chart) to battery using a battery load tester and record battery voltage after No 15 s. Is voltage more than specification? A6E471018520W02 Action Go to Step 3. Go to next step.
CHARGING SYSTEM BATTERY RECHARGING A6E471018520W03 Warning • Keep any flammable away from the battery, otherwise evaporated gas of the battery fluid may catch fire, and cause serious injury or death. Caution • When removing the battery, disconnect the negative battery cable first and install it last to prevent damage to electrical components or the battery. 1. 2. 3. 4. Place a battery in a pan of water to prevent it from overheating. The water level should come up about halfway on the battery.
CHARGING SYSTEM GENERATOR REMOVAL/INSTALLATION A6E471018300W01 Warning • When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery negative cables before performing the following operation. Caution • The generator can be damaged by the heat from the exhaust manifold.
CHARGING SYSTEM GENERATOR INSPECTION A6E471018300W02 Generator Warning Light 1. Verify that the battery is fully charged. • Charge if necessary. 2. Verify that the drive belt deflection/tension is correct. (See B3 DRIVE BELT INSPECTION.) • If not as specified, replace the drive belt. 3. Turn the ignition switch to ON and verify that the generator warning light illuminates. • If not as specified, inspect the generator warning light. 4.
CHARGING SYSTEM , IGNITION SYSTEM Standard current (Reference) Measuring conditions Room temperature: 20 °C {68 ° F} Voltage: 13.5 V Engine hot Engine speed (rpm) 1,000 2,000 * Terminal B current (A) L8 LF L3 0*80 0*90 : Must not be 0 A End Of Sie IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION A6E471218110W01 1. Disconnect the negative battery cable. 2. Remove the plug hole plate.
IGNITION SYSTEM IGNITION COIL INSPECTION Primary Coil Winding 1. Remove the ignition coil. 2. Measure the resistance between the following lead holes using an ohmmeter. • A and B, B and C If not specified, replace the ignition coil. Specification 0.490.57 ohms [20°°C {68°°F}] G A6E4712W003 Secondary Coil Winding 1. Remove the ignition coil. • 1 and 4 • 2 and 3 If not specified, replace the ignition coil. Specification 9.511.
IGNITION SYSTEM Insulation Resistance of Case 1. Disconnect the high-tension lead. 2. Disconnect the ignition coil connector. 3. Measure the insulation resistance between the following terminals and ignition coil case using an ohmmeter. • Terminal B and ignition coil case. If not specified, replace the ignition coil. Specification Above 10 Megohm 4. A6E4712W002 End Of Sie SPARK PLUG REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the plug hoie plate.
IGNITION SYSTEM 6. Install the plug hole plate. Caution • If the plug hole plate interferes with metal clips and the accelerator cable, the cable could be damaged, so when installing follow the procedure below. (1) To position the plug hole plate, grasp the rubber 1 and 2, as shown in the figure, with your hands and press them in. (2) Route the accelerator cable more towards the center of the plug hole plate underside to avoid the rib area as shown in the figure.
STARTING SYSTEM STARTING SYSTEM STARTER REMOVAL/INSTALLATION A6E471418400W01 Warning • When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery negative cables before performing the following operation. 1. 2. 3. 4. Disconnect the negative battery cable. Remove the under cover. Remove the air cleaner assembly.
STARTING SYSTEM STARTER INSPECTION On-vehicle Inspection 1. Verify that the battery is fully charged. 2. Crank the engine and verify that the starter rotates smoothly without any noise. • If not, inspect the following. Remove the starter and inspect the magnetic switch and the starter. Inspect the related wiring harness and the ignition switch. A6E471418400W02 No Load Test 1. Verify that the battery is fully charged. 2. Connect the starter, battery, voltmeter and ammeter as shown. 3.
CLUTCH H LOCATION INDEX .................................................H-2 CLUTCH LOCATION INDEX ...............................H-2 GENERAL PROCEDURES ....................................H-3 PRECAUTION (CLUTCH)....................................H-3 CLUTCH FLUID ......................................................H-4 CLUTCH FLUID INSPECTION ............................H-4 CLUTCH FLUID REPLACEMENT .......................H-4 CLUTCH PEDAL ....................................................
LOCATION INDEX LOCATION INDEX CLUTCH LOCATION INDEX A6E490001036W01 A6E4900W001 .
LOCATION INDEX, GENERAL PROCEDURES 6 7 8 9 Clutch disc (See H14 CLUTCH DISC INSPECTION) Clutch release collar (See H14 CLUTCH RELEASE COLLAR INSPECTION) Flywheel (See H15 FLYWHEEL INSPECTION) Clutch fluid (See H4 CLUTCH FLUID INSPECTION) (See H4 CLUTCH FLUID REPLACEMENT) End Of Sie GENERAL PROCEDURES PRECAUTION (CLUTCH) Clutch Pipe Removal/Installation H A6E491016003W01 Note • A common reservoir is used for the clutch and brake system fluid. 1.
CLUTCH FLUID CLUTCH FLUID CLUTCH FLUID INSPECTION A6E491216010W01 Note • A common reservoir is used for the clutch and brake system fluid. • The fluid in the reservoir must be maintained between the MIN/MAX level during replacement. End Of Sie CLUTCH FLUID REPLACEMENT A6E491216010W02 Caution • Be careful not to spill clutch fluid on a painted surface. If this should happen, wash it off immediately. Note • Do not mix different brands of clutch fluid.
CLUTCH PEDAL CLUTCH PEDAL CLUTCH PEDAL ADJUSTMENT Clutch Pedal Height 1. Measure the distance from the upper surface of the pedal pad to the carpet. • If not as specified, adjust the pedal height by turning adjustment bolt B and locknut A. A6E491441030W01 Pedal height(with carpet) L.H.D.: 210216 mm {8.278.50 in} R.H.D.: 209215 mm {8.238.46 in} H A6E4914W001 Clutch Pedal Free Play 1. Depress the clutch pedal by hand until clutch resistance is felt, and measure the pedal free play.
CLUTCH PEDAL 6. Hold the pedal when the gear noise stops (clutch pedal disengagement point). 7. Measure distance A (the distance from the clutch pedal disengagement point to the fully depressed position) and the pedal stroke. 8. Verify that they are within specification. • If distance A or the pedal stroke is out of specification, adjust the pedal height or the clutch pedal free play to specification. Clutch pedal disengagement stroke Minimum: 20 mm {0.79 in} (Reference value) Pedal stroke 140.0 mm {5.
CLUTCH PEDAL, CLUTCH MASTER CYLINDER 11 12 Pedal pad Clutch pedal (See H7 Clutch Pedal Installation Note) Clutch Pedal Installation Note 1. After installation, adjust the pedal height and free play. (See H5 CLUTCH PEDAL ADJUSTMENT.) End Of Sie CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION 1. 2. 3. 4. Remove the battery and battry tray. (European (L.H.D.), GCC. specs.) Remove in the order indicated in the table. Plug the clutch pipe after removing it to avoid leakage.
CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY A6E491641990W02 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. . A6E4916W002 1 2 3 4 5 Clip Hose Joint Bushing Snap ring (See H8 Snap Ring Disassembly/Assembly Note) 6 7 8 9 10 Piston and secondary cap component Spacer Primary cap Return spring Clutch master cylinder body Snap Ring Disassembly/Assembly Note 1. Hold the piston down using a cloth-wrapped pin punch.
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION A6E491841920W01 1. Remove the under cover. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. .
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY A6E491841920W02 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6E4918W002 .
CLUTCH UNIT CLUTCH UNIT CLUTCH UNIT REMOVAL/INSTALLATION A6E492016000W01 1. Remove in the order indicated in the table. 2. Install in the reverse order oremoval. H A6E4920W001 .
CLUTCH UNIT Clutch Cover and Disc Removal Note 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. 3. Remove the clutch cover and disc. A6E4920W002 Flywheel Removal Note 1. Hold the flywheel using the SST. 2. Remove the bolts evenly and gradually in a crisscross pattern. 3. Remove the flywheel. A6E4920W003 Flywheel Installation Note 1. Install the flywheel to the crankshaft. 2.
CLUTCH UNIT Clutch Disc Installation Note 1. Hold the clutch disc position using the SST. A6E4920W005 Clutch Cover Installation Note 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern. H Tightening torque 18.625.5 N·m {1.92.6 kgf·m, 1419 ft·lbf} A6E4920W006 End Of Sie CLUTCH COVER INSPECTION 1. Measure the wear of the diaphragm spring fingers. • If not as specified, replace the clutch cover. A6E492016410W01 Depth 0.6 mm {0.024 in} max. XME4920W010 2.
CLUTCH UNIT 4. Rotate the flywheel and check for misaligned diaphragm spring fingers. • If not as specified, replace the clutch cover. Misalignment 0.6 mm {0.024 in} max. XME4920W012 End Of Sie CLUTCH DISC INSPECTION 1. Using vernier calipers, measure the thickness of the lining at a rivet head on both sides. • Replace the clutch disc if its thickness is less than the minimum. A6E492016460W01 Thickness 0.3 mm {0.012 in} min. A6E4920W007 2. Measure the clutch disc runout using a dial indicator.
FLYWHEEL FLYWHEEL FLYWHEEL INSPECTION 1. Install a dial gauge on the cylinder block. 2. Measure the flywheel runout using a dial indicator. • If the runout is excessive, replace the flywheel. A6E492211500W01 Runout 0.1 mm {0.004 in} max.
MANUAL TRANSAXLE J LOCATION INDEX ................................................. J-2 MANUAL TRANSAXLE LOCATION INDEX ........ J-2 MANUAL TRANSAXLE.......................................... J-3 TRANSAXLE OIL INSPECTION .......................... J-3 TRANSAXLE OIL REPLACEMENT ..................... J-3 OIL SEAL (DIFFERENTIAL) REPLACEMENT .... J-4 VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION .............................. J-4 VEHICLE SPEEDOMETER SENSOR INSPECTION ........................................
LOCATION INDEX LOCATION INDEX MANUAL TRANSAXLE LOCATION INDEX A6E510001036W01 A6E5100W001 .
MANUAL TRANSAXLE MANUAL TRANSAXLE TRANSAXLE OIL INSPECTION 1. Park the vehicle on level ground. 2. Remove the oil level plug and washer. 3. Verify that the oil is near the brim of the plug port. • If the oil level is lower than the low level, add the specified amount and type of oil through the oil level plug hole. A6E511227001W01 Specified oil grade API Service GL-4 or GL-5 Specified oil viscosity All-season: SAE 75W-90 Above 10 ° C {50 ° F}: SAE 80W-90 4. Install a new washer and the oil level plug.
MANUAL TRANSAXLE OIL SEAL (DIFFERENTIAL) REPLACEMENT 1. 2. 3. 4. On level ground, jack up the vehicle and support it evenly on safety stands. Drain the oil from the transaxle. Remove the front wheels and splash shields. Separate the drive shaft and joint shaft from the transaxle. (See M17 DRIVE SHAFT REMOVAL/ INSTALLATION.) (See M12 JOINT SHAFT REMOVAL/INSTALLATION.) 5. Remove the oil seals using a screwdriver. A6E511219240W01 A6E5112W009 6.
MANUAL TRANSAXLE VEHICLE SPEEDOMETER SENSOR INSPECTION Without ABS 1. Remove the vehicle speedometer sensor. 2. Measure voltage (AC range) between terminals of the vehicle speedometer sensor while the gear is turning. Meter needle Moves slightly under 5 V (AC range) Does not move A6E511217400W02 Action Repair wiring harness between instrument cluster and vehicle speedometer sensor. Replace vehicle speedometer sensor. 3. Install the vehicle speedometer sensor.
MANUAL TRANSAXLE A6E5112W012 . 1 O2 sensor connector 4 2 3 Back-up light switch connector Neutral switch connector 5 J6 Harness bracket Vehicle speedometer sensor connector (GCC specs.
MANUAL TRANSAXLE 6 7 8 9 10 11 12 13 14 15 16 17 Selector cable Shift cable Selector cable bracket Clutch release cylinder Starter Endplate cover Transaxle mounting bolt (upper side) Tie-rod end ball joint (See N11 Tie-rod End Ball Joint Removal Note) Stabilizer control link Damper fork Lower arm (front, rear) ball joint (See R19 Front Lower Arm (Rear) Ball Joint Removal Note) (See R16 Front Lower Arm (Front) Ball Joint Removal Note) Drive shaft (See M17 DRIVE SHAFT REMOVAL/ INSTALLATION.
MANUAL TRANSAXLE Manual Transaxle Installation Note 1. Set the transaxle on a jack and lift into place. 2. Install the transaxle mounting bolts. 3. Tighten the SST (49 E017 5A0)so that the engine is located at the specified position. A6E5112W004 No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note 1. Verify that the engine mount rubbers are installed as shown. 2. By aligning the holes with the stud bolts, install the No.4 engine mount bracket to the transaxle. 3.
SHIFT MECHANISM SHIFT MECHANISM SHIFT MECHANISM REMOVAL/INSTALLATION A6E511446010W01 1. Remove the battery, battery tray and battery bracket. 2. Remove the air cleaner component. (See F10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the dashboard compleat. (See S82 DASHBOARD REMOVAL/INSTALLATION.) 4. Remove the SAS control module. (See T124 SAS UNIT REMOVAL/INSTALLATION.) 5. Remove the climate control unit. (See U44 CLIMATE CONTROL UNIT REMOVAL.) (See U45 CLIMATE CONTROL UNIT INSTALLATION.) 6.
SHIFT MECHANISM Select Cable Installation Note 1. Remove the center console. 2. Make sure that the shift lever (transaxle side) is in neutral. 3. Unlock the lock pice of the select cable (shift lever side) in the order shown in the figure. 4. Shift the sift lever to neutral. A6E5114W002 5. Lock the lock pice of the selector cable (shift cable side) in the order shown in the figure. 6. Install the center console. 7.
AUTOMATIC TRANSAXLE K LOCATION INDEX ................................................. K-4 AUTOMATIC TRANSAXLE LOCATION INDEX............................................ K-4 AUTOMATIC TRANSAXLE.................................... K-6 MECHANICAL SYSTEM TEST ........................... K-6 ROAD TEST ........................................................ K-9 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION .................................................. K-12 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .......
NO.7 NO SHIFTING.........................................K-120 NO.8 DOES NOT SHIFT TO FOURTH GEAR (4GR) ................................................. K-120 NO.9 ABNORMAL SHIFTING.......................... K-122 NO.10 FREQUENT SHIFTING ........................ K-122 NO.11 SHIFT POINT IS HIGH OR LOW .........K-122 NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION ............. K-123 NO.13 NO KICKDOWN.................................... K-123 NO.
K K3
LOCATION INDEX LOCATION INDEX AUTOMATIC TRANSAXLE LOCATION INDEX A6E560001074W01 A6E5600W001 .
LOCATION INDEX 1 2 3 4 5 6 7 8 HOLD switch (See K13 HOLD SWITCH INSPECTION) (See K14 HOLD SWITCH REMOVAL/ INSTALLATION) Transaxle range (TR) switch (See K14 TRANSAXLE RANGE (TR) SWITCH INSPECTION) (See K15 TRANSAXLE RANGE (TR) SWITCH REMOVAL/INSTALLATION) (See K18 TRANSAXLE RANGE (TR) SWITCH ADJUSTMENT) Transaxle fluid temperature (TFT) sensor (See K19 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR INSPECTION) (See K21 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION) Oil pressure swit
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE MECHANICAL SYSTEM TEST A6E561401030W01 Mechanical System Test Preparation 1. Engage the parking brake and use wheel chocks at the front and rear of the wheels. 2. Inspect the engine coolant. (See E3 ENGINE COOLANT LEVEL INSPECTION.) 3. Inspect the engine oil. (See D4 ENGINE OIL INSPECTION.) 4. Inspect the ATF levels. (See K12 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION.) 5. Inspect the idle speed and ignition timing in P position. (See F8 IDLE SPEED INSPECTION.
AUTOMATIC TRANSAXLE 15. Remove the SSTs. 16. Install a new square head plug in the inspection port. Tightening torque 5.09.
AUTOMATIC TRANSAXLE Evaluation of stall test Condition Possible cause Worm oil pump Oil leaking from oil pump, control valve, and/ or transaxle case Insufficient line pressure Pressure regulator valve sticking Pressure control solenoid malfunction Pressure modulator valve sticking Forward clutch slippage One-way clutch 1 slippage One-way clutch 2 slippage 2-4 brake band slippage Low and reverse brake slippage Low and reverse brake slippage Reverse clutch slipping Perform road test to determine whether prob
AUTOMATIC TRANSAXLE ROAD TEST A6E561401030W02 Warning • When performing a road test, be aware of other vehicles, people, impediments, etc. to avoid an accident. Note • When the legal speed limit must be exceeded, use a chassis dynamomenter instead of performing a road test. Road Test Preparation 1. Inspect the engine coolant levels. (See E3 ENGINE COOLANT LEVEL INSPECTION.) 2. Inspect the engine oil levels. (See D4 ENGINE OIL INSPECTION.) 3. Inspect the ATF levels.
AUTOMATIC TRANSAXLE 8. Accelerate the vehicle at half throttle and WOT, and verify that 4→3, 3→2, and 2→3 shift can be obtained. The shift points must be as shown in the table below. • If not as specified, inspect the PCM and ATX. (See K113 SYMPTOM TROUBLESHOOTING ITEM TABLE.) 9. Drive the vehicle in 4GR, 3GR, 2GR and verify that kickdown does not occur. • If not as specified, inspect the PCM and ATX. (See K113 SYMPTOM TROUBLESHOOTING ITEM TABLE.) 10.
AUTOMATIC TRANSAXLE 7. Accelerate the vehicle in 2GR at half throttle and WOT, and verify that 2GR is held. • If not as specified, inspect the PCM and ATX. (See K113 SYMPTOM TROUBLESHOOTING ITEM TABLE.) 8. Decelerate the vehicle and verify that engine braking effect is felt. • If not as specified, inspect the PCM and ATX. (See K113 SYMPTOM TROUBLESHOOTING ITEM TABLE.
AUTOMATIC TRANSAXLE P Position Test 1. Shift into P position on a gentle slope. Release the brake and verify that the vehicle does not roll. End Of Sie AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION Automatic Transaxle Fluid (ATF) Condition Inspection 1. One way of determining whether the transaxle should be disassembled is by noting: • If the ATF is muddy or varnished. • If the ATF smells strange or unusual.
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT A6E561401030W04 Warning • When the transaxle and ATF are hot, they can badly burn you. Turn off the engine and wait until they are cool before changing the ATF. 1. 2. 3. 4. Remove the oil dipstick. Remove the oil drain plug and washer. Drain the ATF into a container. Install a new washer and the drain plug. Tightening torque 3041 N·m {3.04.2 kgf·m, 2230 ft·lbf} 5.
AUTOMATIC TRANSAXLE Continuity Inspection of 1. Disconnect the negative battery cable. 2. Remove the console. 3. Disconnect the HOLD switch connector. 4. Inspect continuity at the HOLD switch. • If the switch is okay, inspect the wiring harness. (HOLD switchPCM, HOLD switchBody ground) • If not as specified, replace the HOLD switch. (See K14 HOLD SWITCH REMOVAL/ INSTALLATION.) 5. Connect the HOLD switch connector. 6. Install the console. 7. Connect the negative battery cable.
AUTOMATIC TRANSAXLE 3. Disconnect the TR switch connector. A6E5614W008 4. Inspect for continuity at the TR switch. • If not as specified, adjust the TR switch and go to Step 4. 5. Reinspect for continuity at TR switch. • If not as specified, replace the TR switch. (See K15 TRANSAXLE RANGE (TR) SWITCH REMOVAL/INSTALLATION.) 6. Connect the TR switch connector. 7. Install the air cleaner component. (See F10 INTAKE-AIR SYSTEM REMOVAL/ INSTALLATION.) 8. Connect the negative battery cable.
AUTOMATIC TRANSAXLE 7. Remove the manual shaft lever. 8. Remove the TR switch. A6E5614W012 9. Rotate the manual shaft to the converter housing side fully, then return 2 notches to set the N position. A6E5614W013 10. Turn the protrusion at resistance between the terminals B and C become 750 ohms. A6E5614W014 A6E5614W010 11. Install the TR switch while aligning the protrusion and groove as shown. 12. Hand-tighten the TR switch mounting bolts.
AUTOMATIC TRANSAXLE 13. Inspect the resistance between the terminals B and C. • If not as specified, readjust the TR switch. (See K18 TRANSAXLE RANGE (TR) SWITCH ADJUSTMENT.) Resistance 750 ohms 14. Tighten the TR switch mounting bolts. Tightening torque 811 N·m {82112 kgf·cm, 7197 in·lbf} A6E5614W010 Caution • Do not use an impact wrench. Hold the manual shaft lever when removing the manual shaft nut, or the transaxle may be damaged. 15. Install the manual shaft lever and the washer.
AUTOMATIC TRANSAXLE 20. Connect the selector cable. 21. Inspect for continuity at the TR switch. (See K14 TRANSAXLE RANGE (TR) SWITCH INSPECTION.) • If not as specified, readjust the TR switch. (See K18 TRANSAXLE RANGE (TR) SWITCH ADJUSTMENT.) 22. Connect the TR switch connector. 23. Install the aircleaner component. (See F10 INTAKE-AIR SYSTEM REMOVAL/ INSTALLATION.) 24. Connect the negative battery cable. 25. Inspect operation of the TR switch. (See K14 TRANSAXLE RANGE (TR) SWITCH INSPECTION.
AUTOMATIC TRANSAXLE 6. Loosen the TR switch mounting bolts. A6E5614W020 7. Measure the resistance between the terminals B and C. 8. Adjust the switch to the point as follow. Resistance standard value 750 ohms K 9. Tighten the TR switch mounting bolts. Tightening torque 811 N·m {82112 kgf·cm, 7197 in·lbf} A6E5614W010 10. Move the selector lever to N position. 11. Verify that the TR switch is aligned with N position. 12. Connect the TR switch connector. 13.
AUTOMATIC TRANSAXLE 3. Disconnect the transaxle connector. A6E5614W021 4. Measure the resistance between the terminals E and H. • If it is out of specification, perform the offvehicle inspection of TFT sensor. (See K21 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION.) ATF temperature (°°C {°°F}) 20 {4} 0 {32} 20 {68} 40 {104} 60 {140} 80 {176} 100 {212} 120 {248} 130 {266} Resistance (kilohm) 236324 84.3110 33.542.0 14.717.9 7.088.17 3.614.15 1.962.24 1.131.28 0.870.
AUTOMATIC TRANSAXLE 5. Measure resistance between the terminals of the TFT sensor. • If not as specified, replace the TFT sensor. (See K21 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/ INSTALLATION.) ATF temperature (°°C {°°F}) -20 {-4} 0 {32} 20 {68} 40 {104} 60 {140} 80 {176} 100 {212} 120 {248} 130 {266} Resistance (kilohm) 236324 84.3110 33.542.0 14.717.9 7.088.17 3.614.15 1.962.24 1.131.28 0.870.98 A6E5614W024 6.
AUTOMATIC TRANSAXLE 3. Disconnect the cord assembly connector. A6E5614W026 4. Verify that there is no continuity between cord assembly terminal and ground. • If as continuity, inspect the cord assembly. • If the cord assembly is okay, inspect the oil pressure switch. (See K22 On-vehicle Inspection (oil pressure switch inspection).) 5. Connect the cord assembly connector. 6. Install the under cover. 7. Connect the negative battery cable.
AUTOMATIC TRANSAXLE Off-vehicle inspection 1. Remove the oil pressure switch. 2. Apply air pressure at 400440 kPa {4.14.4kgf/cm2,5863psi} 3. Inspect continuity the between oil pressure switch terminal and screw part. • If not as continuity, replace the oil pressure switch. (See K23 OIL PRESSURE SWITCH REMOVAL/INSTALLATION.) 4. Install the oil pressure switch.
AUTOMATIC TRANSAXLE 5. Measure resistance between the terminals of the input/turbine speed sensor. • If not as specified, replace the input/turbine speed sensor. Resistance 250600 ohms (ATF temperature: 40160 °C {40320 ° F}) 6. Connect the input/turbine speed sensor connector. 7. Install the air cleaner component. (See F10 INTAKE-AIR SYSTEM REMOVAL/ INSTALLATION.) 8. Install the battery and battery tray. 9. Connect the negative battery cable.
AUTOMATIC TRANSAXLE 6. Inspect wave profile. • PCM terminal: 3C (+) - 1D (-) • Oscilloscope setting: 1 V/DIV (Y), 2.5 ms/DIV (X), DC range • Vehicle condition: drive the vehicle with 32 km/h{20 mph} If wave profile or voltage are out of specifications, carry out the Open Circuit Inspection or Short Circuit Inspection A6E5614W102 Power Supply Voltage Inspection 1. Disconnect the VSS connector. 2. Turn the ignition switch to ON. 3. Measure voltage at VSS connector terminal B (wiring harness side).
AUTOMATIC TRANSAXLE VEHICLE SPEEDOMETER SENSOR (VSS) REMOVAL/INSTALLATION A6E561401030W06 Caution • Water or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it. • If foreign materials are stuck to the VSS, disturbance by magnetic flux can cause sensor output to be abnormal and thereby negatively affect control.
AUTOMATIC TRANSAXLE 4. Measure the resistance between the following terminals. • If not as specified, inspect the ground, then perform the operating inspection. ATF temperature: 40150 °C {40302 ° F} Terminal Solenoid valve AGND CGND GGND BGND FGND DI Shift solenoid A Shift solenoid B Shift solenoid C Shift solenoid D Shift solenoid E Pressure control Resistance (ohm) 1.04.2 1.04.2 1.04.2 10.926.2 10.926.2 2.47.3 A6E5614W039 5. Connect the transaxle connector. 6.
AUTOMATIC TRANSAXLE Pressure control solenoid Resistance 2.47.3 ohms (ATF temperature: 40150 ° C {40302 °F}) A6E5614W041 Shift solenoid A, B, C Resistance 1.04.2 ohms (ATF temperature: 40150 ° C {40302 °F}) A6E5614W042 Shift solenoid D, E Resistance 10.926.2 ohms (ATF temperature: 40150 ° C {40302 °F}) A6E5614W043 End Of Sie VALVE REMOVAL/INSTALLATION SOLENOID 1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the under cover. Remove the control valve body.
AUTOMATIC TRANSAXLE 6. Install the solenoid valve in the control valve body. Tightening torque 7.810.8 N·m {80110 kgf·cm, 7095.4 in·lbf} 7. Install the control valve body. (See K34 CONTROL VALVE BODY REMOVAL.) 8. Install the under cover. 9. Connect the negative battery cable. 10. Add ATF and, with the engine idling, inspect the ATF level and inspect for leakage. (See K12 Automatic Transaxle Fluid (ATF) Level Inspection.) 11. Carry out the mechanical system test. (See K6 MECHANICAL SYSTEM TEST.) 12.
AUTOMATIC TRANSAXLE A6E5614W046 .
AUTOMATIC TRANSAXLE 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 TR switch connector Transaxle connector VSS connector Oil dipstick and filler tube Harness bracket Oil hose Selector cable Transaxle mounting bolt (upper side) Starter Endplate cover Tie-rod end ball joint (See N11 Tie-rod End Ball Joint Removal Note) Stabilizer control link Damper fork Lower arm (front, rear) ball joint (See R19 Front Lower Arm (Rear) Ball Joint Removal Note) (See R16 Front Lower Arm (Front) Ball Joint Removal Note) Drive sha
AUTOMATIC TRANSAXLE 4. Remove the transaxle. A6E5614W051 Transaxle Installation Note 1. Set the transaxle on a jack and lift it. 2. Install the transaxle mounting bolts. Tightening torque 37.352 N·m {3.85.3 kgf·m, 2838 ft·lbf} A6E5614W052 Torque Converter Nuts Removal Note 1. Hold the cankshaft pulley to prevent drive plate from rotating. A6E5614W091 2. Remove the torque converter nuts from the starter installation hole.
AUTOMATIC TRANSAXLE Torque Converter Nuts Installation Note 1. Hold the cankshaft pulley to prevent drive plate from rotating. Caution • Loosely and equally tighten the torque converter nuts, then further tighten them to the specified tightening torque. A6E5614W091 2. Tighten the torque converter mounting nuts. Tightening torque 34.360.8 N·m {3.56.2 kgf·m, 2545 ft·lbf} K A6E5614W092 No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note 1.
AUTOMATIC TRANSAXLE • The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines contact the oil seal. 2. Remove the drive shaft. (See M17 DRIVE SHAFT REMOVAL/INSTALLATION.) 3. Remove the oil seal. 4. Using the SST and a hammer, tap a new oil seal in evenly until the SST contacts the transaxle case. 5. Coat the lip of the oil seal with transaxle oil. 6. Install the drive shaft. (See M17 DRIVE SHAFT REMOVAL/INSTALLATION.) 7. Add ATF to the specified level.
AUTOMATIC TRANSAXLE 10. Remove the accumulators and accumulator springs. A6E5614W059 End Of SieVALVE BODY INSTALLATION CONTROL A6E561421100W02 On-Vehicle Installation Caution • Be sure to align the parking rod and the manual valve. K A6E5614W060 1. Install the accumulator springs and accumulators into the transaxle case.
AUTOMATIC TRANSAXLE 2. Install the control valve body component. Tightening torque 7.810.8 N·m {80110 kgf·cm, 7095 in·lbf} Bolt length (measured from below the head) B: 40 mm {1.575 in} No mark: 70 mm {2.756 in} 3. Install the oil strainer. 4. Match the harness colors, then connect the solenoid connector and TFT sensor connector.
AUTOMATIC TRANSAXLE 1. Remove the two oil cooler line hoses and apply air pressure of 196 kPa {2.0 kgf/cm2, 28 psi} from the return hose (pipe) side. Caution • Power flushing should be performed very carefully when removing the accumulated debris from the fluid baffle, otherwise the debris cannot be removed or the problem becomes even worse. 2. If there is no air blown out the feed side, flush the oil cooler lines using the power-flushing tool.
AUTOMATIC TRANSAXLE Power Flushing Repair procedure 1. Before power flushing, inspect the hoses/lines and clamps. Power flushing must begin with back flushing followed by forward flushing to quickly dislodge the restriction. If back flushing is not performed before forward flushing, the restriction could further reduce the ATF flow through the internal mesh type baffle of the cooler and flushing will not be effective or possible. Inspecting oil lines and clamps 1.
AUTOMATIC TRANSAXLE OIL COOLER REMOVAL/INSTALLATION A6E561419900W02 1. Disconnect the negative battery cable. 2. Drain the ATF into a container. (See K13 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.) 3. Remove the radiator. (See E6 RADIATOR REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Add ATF to the specified level. (See K13 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.) 7. Connect the negative battery cable. 8.
AUTOMATIC TRANSAXLE WITHOUT OIL COOLER A6E5614W080 . 1 2 3 Oil hose (See K40 Oil Pipe, Hose Clamp, Oil Hose Installation Note.) Hose clamp (See K40 Oil Pipe, Hose Clamp, Oil Hose Installation Note.) Connector bolt 4 5 O-ring Radiator (in tank oil cooler) (See K40 Radiator (In Tank Oil Cooler) Installation Note.) Radiator (In Tank Oil Cooler) Installation Note 1.
AUTOMATIC TRANSAXLE 2. Align the marks, and slide the oil hose onto the oil pipe until it is fully seated as shown. Note • If reusing the hose, install the new hose clamp exactly on the mark left by the previous hose camp.Then apply force to the hose clamp in the direction of the arrow in order to fit the clamp in the place. 3. Install the new hose clamp onto the hose. 4. Verify that the hose clamp does not interfere with any other components.
AUTOMATIC TRANSAXLE Radiator Outer Tank (In Tank Oil Cooler) Removal Note 1. Inspect the height of the header tabs. 2. Insert the end of a medium tip screwdriver between the end of the header tab and the outer tank. Note • Do not open more tabs than necessary for tank removal. A6E5614W073 3. Pivot the screwdriver to pry the tab away from the tank and repeat the procedure for each tab. 4. Remove the radiator outer tank and O-ring (gasket) from the core header when all of the tabs are opened.
AUTOMATIC TRANSAXLE 4. Squeeze the header tabs down in order as shown against the lip of radiator outer tank base with locking-type pliers while rotating the pliers toward the tank. K A6E5614W076 5. Verify the height of the header tabs is same as the height before removal. 6. Inspect for leakage from radiator. (See E4 ENGINE COOLANT LEAKAGE INSPECTION.) A6E5614W073 End OfPLATE Sie REMOVAL/INSTALLATION DRIVE 1. Remove the transaxle.(See K29 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION.) 2.
AUTOMATIC TRANSAXLE Drive Plate Mounting Bolts Removal Note 1. Set the SST or equivalent against the drive plate. 2. Remove the bolts and the drive plate. A6E5614W079 Drive Plate Installation Note Caution • If the bolts are reused, remove the oil sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage. 1. Remove the sealant from the bolts hole in the crankshaft and from the drive plate mounting bolts.
AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM SHIFT-LOCK INSPECTION 1. Turn the ignition switch to ON position. 2. Verify that the selector lever is in P position. 3. Depress the brake pedal and verify that the selector lever can be shifted from P position. • If a malfunction is found, inspect the interlock cable. (See K45 INTERLOCK CABLE INSPECTION.) A6E561630000W01 End Of Sie KEY INTERLOCK INSPECTION A6E561609000W01 1.
AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR CABLE ADJUSTMENT 1. Remove the center console. 2. Shift the selector lever to P position. 3. Unlock the lock piece of the selector cable (selector lever side) in the order shown in the figure. 4. Verify that the manual shaft is in P position. A6E561646102W02 A6E5616W003 5. Lock the lock piece of the selector cable (selector lever side) in the order shown in the figure. 6. Install the center console. 7.
AUTOMATIC TRANSAXLE SHIFT MECHANISM 11. Install in the reverse order of removal. . K A6E5616W005 1 2 3 4 Column cover(with key interlock) Clip(with key interlock) Clip(with key interlock) Interlock cable(with key interlock) (See K49 Interlock Cable Installation Note.) 5 6 Selector cable (See K48 Selector Cable Removal Note.) (See K48 Selector Cable Installation Note.
AUTOMATIC TRANSAXLE SHIFT MECHANISM Selector Cable Removal Note 1. Remove the clip. 2. Remove the selector cable. A6E5616W006 Selector Cable Installation Note 1. Install the selector cable to the selector lever certainly. 2. Install the selector cable to the bracket certainly. Note • Step 3, 4 is for the selector cable replacement only. 3. Verify that the selector lever is in P position. A6E5616W020 4. Lock the lock piece of the selector cable (selector lever side) in the order shown in the figure.
AUTOMATIC TRANSAXLE SHIFT MECHANISM Caution • Bending the selector cable in the manner shown in the figure will damage the cable and it may become loose when shifted. When installing the selector cable, hold it straight. Note • Install the selector lever to the manual shaft lever with the spring side of the selector cable end facing the front of the vehicle. A6E5616W008 6. Install the selector lever to the manual shaft lever in such a way that the selector cable does not bear a load. 7.
AUTOMATIC TRANSAXLE SHIFT MECHANISM 6. Press the interlock cable lock piece in unitl it is locked. Note • Step 7 is for the interlock cable replacement only. A6E5616W012 7. Remove the lock unit pin as shown in the figure. 8. Turn the ignition key in ACC position. 9. Install the interlock cable to the key cylinder. A6E5616W013 10. Slide the outer casing to the key cylinder, and insert the clip over the convex part of the outer casing.
AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR LEVER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. A6E561646102W04 . K A6E5616W015 1 2 3 Connector (See K51 Connector Disassembly Note.) Selector lever knob component Cover 4 5 6 Indicator panel Selector illumination light Selector lever Connector Disassembly Note 1. Insert a thin piece of metal from the terminal side of the connector, and press down the terminal locking tab. 2.
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD A6E567001030W01 • When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL), HOLD indicator light flashing, and PCM memory for diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. If the DTC exists, diagnose the applicable DTC. (See K53 DTC TABLE.
ON-BOARD DIAGNOSTIC 9. Drive the vehicle in D range and shift gears between 1st and 4th (TCC operation) gear. 10. Gradually slow down and stop the vehicle. 11. Make sure that the repaired DTC does not recur. End Of Sie DTC TABLE A6E567001030W04 DTC No.
ON-BOARD DIAGNOSTIC DTC No.
ON-BOARD DIAGNOSTIC DTC No.
ON-BOARD DIAGNOSTIC DTC P0500 Vehicle speed sensor (VSS) circuit malfunction Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED SERVICE INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair Information available? 3 4 5 INSPECT VSS CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect VSS connector.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Disconnect PCM connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.). • Is connection okay? 7 INSPECT VEHICLE SPEED SIGNAL CIRCUIT FOR OPEN • Disconnect PCM connector and VSS connector. • Inspect for continuity between VSS terminal B and PCM terminal 3C.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 5 INSPECT TR SWITCH • Turn ignition key to OFF. • Disconnect TR switch connector. • Inspect for resistance between TR switch terminals B and C (part-side).
ON-BOARD DIAGNOSTIC DTC P0707 Transaxle range (TR) switch circuit low input K Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 INSPECT TR SWITCH CONNECTOR • Turn ignition key OFF. • Disconnect TR switch connector.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT TR SWITCH SIGNAL CIRCUIT FOR SHORT TO GROUND • Turn ignition key to OFF. • Disconnect PCM connector • Check for continuity between TR switch terminal C (harness-side) and body ground. • Is there continuity? 6 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Disconnect PCM connector. • Check for poor connection at terminals 1W and 2H (damaged/pulled-out pins, corrosion, etc.).
ON-BOARD DIAGNOSTIC DTC P0708 Transaxle range (TR) switch circuit high input K Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 INSPECT TR SWITCH CONNECTOR FOR POOR CONNECTION • Turn ignition key OFF. • Disconnect TR switch connector.
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT TR SWITCH • Turn ignition key to OFF. • Disconnect TR switch connector. • Inspect for resistance between TR switch terminals B and C (part-side). • Is resistance okay? (See K14 TRANSAXLE RANGE (TR) SWITCH INSPECTION.) 5 INSPECT TR SWITCH SIGNAL CIRCUIT FOR SHORT TO POWER • Turn ignition key to ON (engine OFF). • Measure the voltage between TR switch terminal C (harness-side) and body ground.
ON-BOARD DIAGNOSTIC DTC P0711 DTC P0711 A6E567001030W09 Transaxle fluid temperature (TFT) sensor circuit range/performance (stuck) • When all conditions below are satisfied. When 180 seconds have passed after engine is started, vehicle is driven for 150 seconds or more at vehicle speed between 25 59 km/h {15 36 mph}, then 60 km/h {37 mph} or more for 100 seconds or more. P0712, P0713 not output. Variation in ATF voltage below 0.06 V.
ON-BOARD DIAGNOSTIC End Of Sie DTC P0712 DTC P0712 DETECTION CONDITION POSSIBLE CAUSE A6E567001030W10 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground) • If PCM detects either of following conditions for 150 seconds or more, PCM determines that TFT sensor circuit has a malfunction. TFT sensor voltage is 0.06 V or below and vehicle speed 20 km/h {12 mph} or above. Diagnostic support note: • • • • • • • • • • • • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 VERIFY CURRENT INPUT SIGNAL STATUS • Turn ignition key to OFF. • Connect breakout box to PCM. • Turn ignition key to ON (engine OFF). • Measure the voltage at PCM terminal 3D. • Are voltage readings above 0.06 V? 4 INSPECT TERMINAL CONDITION • Turn ignition key to OFF. • Disconnect ATX connector. • Inspect for bent terminals. • Are the terminals bent? 5 INSPECT TFT SENSOR CIRCUIT • Turn ignition key to ON (engine OFF). • Verify if voltage changes to 4.
ON-BOARD DIAGNOSTIC DTC P0713 POSSIBLE CAUSE Transaxle fluid temperature (TFT) sensor circuit malfunction (open circuit) • TFT sensor malfunction • Open circuit between TFT sensor terminal A and ATX connector terminal E • Open circuit between TFT sensor terminal B and ATX connector terminal H • Open circuit between ATX connector terminal E and PCM terminal 3D • Open circuit between ATX connector terminal H and PCM terminal 2H • Damaged connectors between TFT sensor and PCM • PCM malfunction Diagnostic pr
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT TFT SENSOR CIRCUIT • Turn ignition key to ON (engine OFF). • Measure the voltage at PCM terminal 3D when connect between ATX connector terminals E and H (vehicle harness-side) using jumper wire. • Verify that voltage changes to 0.06 V or below. • Does voltage change? 6 INSPECT TFT SENSOR CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Remove valve body cover. • Disconnect TFT sensor connector.
ON-BOARD DIAGNOSTIC DTC P0715 DTC P0715 DETECTION CONDITION POSSIBLE CAUSE A6E567001030W12 Input/turbine speed sensor circuit malfunction • When all conditions below satisfied and 0.7 second or more have passed. D, S or L range of TR switch input. Driving vehicle with vehicle speed 40 km/h {25 mph} or above. Input/turbine speed sensor signal not input. Diagnostic support note: • • • • • • • • • • • • • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 VERIFY CURRENT INPUT SIGNAL STATUS • Turn ignition key to OFF. • Start engine. • Measure frequency of input/turbine speed sensor using a oscilloscope. IG ON: 0 Hz Idle: Within 320374 Hz (P, N position) • Are frequency of input/turbine speed sensor readings within specifications? 4 INSPECT INPUT/TURBINE SPEED SENSOR CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect input/turbine speed sensor connector.
ON-BOARD DIAGNOSTIC DTC P0731 DTC P0731 A6E567001030W13 Gear 1 incorrect (Incorrect Gear Ratio Detected) • PCM monitors revolution ratio of forward clutch drum revolution to differential gear case revolution when the following monitoring conditions are met. If revolution ratio is below 2.157, PCM determines that there is malfunction. Monitoring condition: ATF temperature 20 °C {68 °F} or above. Driving in 1GR in D range. Engine run. Turbine speed within 2254,988 rpm. Throttle opening angle 5.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 INSPECT STALL SPEED • Measure stall speed in D range. (See K7 Stall Test.) Specification 2,0002,600 rpm • Is stall speed within specification? 7 INSPECT FREQUENCY OF INPUT/TURBINE SPEED SENSOR WHEN DRIVING VEHICLE • Turn ignition key to OFF. • Connect WDS or equivalent. • Start engine.
ON-BOARD DIAGNOSTIC DTC P0732 POSSIBLE CAUSE Gear 2 incorrect (Incorrect Gear Ratio Detected) • ATF level low • Deteriorated ATF • Shift solenoids A, B or C stuck • Pressure control solenoid stuck • Line pressure low • 2-4 brake band slipping • Forward clutch slipping • Control valve stuck • Oil pump • PCM malfunction Diagnostic procedure STEP INSPECTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability.
ON-BOARD DIAGNOSTIC STEP INSPECTION 8 VERIFY REPAIR OF DTC P0732 • Make sure to reconnect all disconnected connectors. • Clear DTC using WDS or equivalent. • Start engine. • Warm up transaxle. • Drive vehicle under the following conditions at least 4 times for more than 1 seconds. ATF temperature: 20 °C {68 °F} or above Drive in D range, 2nd gear Vehicle speed (VSS PID): 3.8 km/h {2.4 mph} or above • Are any DTCs present? 9 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 CHECK ATF LEVEL • Start engine. • Warm up ATX. • Is ATF level within specification? (See K12 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION.) 4 INSPECTION SHIFT SOLENOID VALVE A AND C FOR CLICK SOUND • Perform inspection of operation. (See K26 SOLENOID VALVE INSPECTION.) • Verify the click sound of shift solenoid A and C when applying B+ to each transaxle connector terminal. • Was click heard from solenoids? 5 INSPECT LINE PRESSURE • Start engine.
ON-BOARD DIAGNOSTIC DTC P0734 DTC P0734 A6E567001030W16 Gear 4 incorrect (Incorrect Gear Ratio Detected) • PCM monitors revolution ratio of forward clutch drum revolution to differential gear case revolution when the following monitoring conditions are met. If revolution ratio is below 0.6 or above 1.249, PCM determines that there is malfunction. Monitoring condition: ATF temperature 20 °C {68 °F} or above. Driving in 4 GR in D range. Engine run. Turbine speed within 2254,988 rpm.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT LINE PRESSURE • Start engine. • Measure line pressures. Specification Idle: 330470 kPa {3.44.7 kgf/cm2, 4966 psi} Stall: 1,1601,320 kPa {11.913.4 kgf/cm2, 170190 psi} • Is line pressure within specification? (See K6 Line Pressure Test.) 6 INSPECT STALL SPEED • Measure stall speed in D range. (See K7 Stall Test.
ON-BOARD DIAGNOSTIC DTC P0741 A6E567001030W17 DTC P0741 Torque converter clutch (TCC) stuck OFF • When all conditions below satisfied. ATF temperature 20 °C {68 °F} or above. Driving in 4GR at D range. Engine run. Turbine speed within 2254,988 rpm. Vehicle speed within 60100 km/h {3762 mph}.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body. • Is each valve operation okay and is return spring okay? (See K34 CONTROL VALVE BODY REMOVAL, K35 CONTROL VALVE BODY INSTALLATION.) (See ATX Workshop Manual FN4A-EL (9999-95FN4A-99).) 6 VERIFY TROUBLESHOOTING OF DTC P0741 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory using WDS or equivalent.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 2 3 4 5 6 CHECK ATF CONDITION • Turn ignition key to OFF. • Check ATF condition. Clear red: Normal Milky: Water mixed in fluid Reddish brown: Deteriorated ATF • Is it okay? (See K12 Automatic Transaxle Fluid (ATF) Condition Inspection.) CHECK ATF LEVEL • Start engine. • Warm up ATX.
ON-BOARD DIAGNOSTIC STEP INSPECTION 7 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See K52 AFTER REPAIR PROCEDURE.) • Are any DTCs present? ACTION Yes Go to applicable DTC inspection. No Troubleshooting completed.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 2 3 4 5 6 7 8 9 INSPECT ATX CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect ATX connector. • Check for poor connection (damaged/pulledout terminal, corrosion, etc.).
ON-BOARD DIAGNOSTIC STEP INSPECTION 10 VERIFY TROUBLESHOOTING OF DTC P0745 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory using WDS or equivalent. • Make sure to wait more than 1 second after turning ignition key to ON. • Are any DTCs present? 11 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See K52 AFTER REPAIR PROCEDURE.) • Are any DTCs present? End Sie DTC Of P0751 ACTION Yes Replace PCM, then go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT LINE PRESSURE • Start engine. • Measure line pressure. Specification Idle: 330470 kPa {3.44.7 kgf/cm2, 4966 psi} Stall: 1,1601,320 kPa {11.913.4 kgf/cm2, 170190 psi} • Is line pressure within specification? (See K6 Line Pressure Test.) 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 5 6 7 8 CHECK ATF CONDITION • Turn ignition key to OFF. • Check ATF condition.
ON-BOARD DIAGNOSTIC DTC P0753 DTC P0753 DETECTION CONDITION POSSIBLE CAUSE A6E567001030W22 Shift solenoid A malfunction (electrical) • If PCM detects either of following conditions, PCM determines that shift solenoid A circuit has a malfunction: Shift solenoid A voltage is stuck at B+ after engine start. Shift solenoid A voltage is stuck at 0 V after engine start. Diagnostic support note: • • • • • • • • • • • • • • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 5 6 7 8 9 10 INSPECT ATX CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect ATX connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.).
ON-BOARD DIAGNOSTIC STEP INSPECTION 11 VERIFY TROUBLESHOOTING OF DTC P0753 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory using WDS or equivalent. • Drive vehicle in D range and make sure that gears shift smoothly from 1GR to 4GR. • Are any DTCs present? 12 VERIFY AFTER REPAIR PROCEDURE • Perform After Repair Procedure. (See K52 AFTER REPAIR PROCEDURE.) • Are any DTCs present? End Of Sie DTC P0756 ACTION Yes Replace PCM, then go to next step.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT LINE PRESSURE • Start engine. • Measure line pressure. Specification Idle: 330470 kPa {3.44.7 kgf/cm2, 4966 psi} Stall: 1,2001,360 kPa {12.313.8 kgf/cm2, 175196 psi} • Is line pressure within specification? (See K6 Line Pressure Test.) 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body.
ON-BOARD DIAGNOSTIC DTC P0757 A6E567001030W24 DTC P0757 Shift solenoid B stuck ON • When either of DTC P0731 and P0733 are not generated, and both the following conditions are satisfied. When all conditions below satisfied while driving in 2GR. • ATF temperature 20 °C {68 °F} or above. • Driving in D range. • Engine run. • Turbine speed within 2254,988 rpm. • Differential gear case (output) revolution speed 35 rpm or above.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT LINE PRESSURE • Start engine. • Measure line pressure. Specification Idle: 330470 kPa {3.44.7 kgf/cm2, 4966 psi} Stall: 1,2001,360 kPa {12.313.8 kgf/cm2, 175196 psi} • Is line pressure within specification? (See K6 Line Pressure Test.) 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body.
ON-BOARD DIAGNOSTIC DTC P0758 POSSIBLE CAUSE Shift solenoid B malfunction (electrical) • Shift solenoid B malfunction • Short to ground between ATX connector terminal C and PCM terminal 4AC • Short to power between ATX connector terminal C and PCM terminal 4AC • Open circuit between shift solenoid B terminal B and ATX connector terminal C • Open circuit between ATX connector terminal C and PCM terminal 4AC • Open circuit between shift solenoid B terminal A and body ground point • Damaged connector between
ON-BOARD DIAGNOSTIC STEP INSPECTION 4 INSPECT RESISTANCE • Inspect resistance between ATX connector terminal C (transaxle case side) and body ground. • Is resistance within 1.04.2 ohms? (See K26 Resistance Inspection (On-Vehicle Inspection).) 5 INSPECT SHIFT SOLENOID B CONNECTOR FOR POOR CONNECTION • Disconnect shift solenoid B connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.).
ON-BOARD DIAGNOSTIC DTC P0761 A6E567001030W26 DTC P0761 Shift solenoid C stuck OFF • When either of DTC P0733 and P0734 are not generated, and both the following conditions are satisfied. When all conditions below satisfied while driving in 1GR. • ATF temperature 20 °C {68 °F} or above. • Driving in D range. • Engine run. • Turbine speed within 2254,988 rpm. • Throttle opening angle (TP PID) 5.67% or above. • Differential gear case (output) revolution speed 35 rpm or above.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT LINE PRESSURE • Start engine. • Measure line pressure. Specification Idle: 330470 kPa {3.44.7 kgf/cm2, 4966 psi} Stall: 1,2001,360 kPa {12.313.8 kgf/cm2, 175196 psi} • Is line pressure within specification? (See K6 Line Pressure Test.) 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body.
ON-BOARD DIAGNOSTIC DTC P0762 A6E567001030W27 DTC P0762 Shift solenoid C stuck ON • When either of DTC P0731 and P0732 are not generated, and both the following conditions are satisfied. When all conditions below satisfied while driving in 3GR. • ATF temperature 20 °C {68 °F} or above. • Driving in D range. • Engine run. • Turbine speed within 2254,988 rpm. • Differential gear case (output) revolution speed 35 rpm or above.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT LINE PRESSURE • Start engine. • Measure line pressure. Specification Idle: 330470 kPa {3.44.7 kgf/cm2, 4966 psi} Stall: 1,2001,360 kPa {12.313.8 kgf/cm2, 175196 psi} • Is line pressure within specification? (See K6 Line Pressure Test.) 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body.
ON-BOARD DIAGNOSTIC DTC P0763 Shift solenoid C malfunction (electrical) K Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 INSPECT ATX CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect ATX connector.
ON-BOARD DIAGNOSTIC STEP INSPECTION 5 INSPECT SHIFT SOLENOID C CONNECTOR FOR POOR CONNECTION • Disconnect shift solenoid C connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.). • Is connection okay? 6 INSPECT RESISTANCE • Inspect resistance between shift solenoid C terminals A and B (part-side). • Is resistance within 1.04.2 ohms? (See K27 Resistance Inspection (Off-Vehicle Inspection).
ON-BOARD DIAGNOSTIC DTC P0766 A6E567001030W29 DTC P0766 Shift solenoid D stuck OFF • When any of DTC P0731, P0732, and P0733 not output (correct judgment), and all conditions below are satisfied. ATF temperature 20 °C {68 °F} or above. Driving in 4GR at D range. Engine run. Turbine speed within 2254,988 rpm. Differential gear case (output) revolution speed 35 rpm or above. Vehicle speed 50 km/h {31 mph} or above. Throttle opening angle closed throttle position.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body. • Is each valve operation okay and is return spring okay? (See K34 CONTROL VALVE BODY REMOVAL, K35 CONTROL VALVE BODY INSTALLATION.) (See ATX Workshop Manual FN4A-EL (9999-95FN4A-99).) 7 8 VERIFY TROUBLESHOOTING OF DTC P0766 COMPLETED • Make sure to reconnect all disconnected connectors.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 5 6 7 8 CHECK ATF CONDITION • Turn ignition key to OFF. • Check ATF condition.
ON-BOARD DIAGNOSTIC DTC P0768 DTC P0768 DETECTION CONDITION POSSIBLE CAUSE A6E567001030W31 Shift solenoid D malfunction (electrical) • If PCM detects either of following conditions while driving in 4GR at D range, PCM determines that shift solenoid D circuit has a malfunction: Shift solenoid D voltage is stuck at B+ after engine start. Shift solenoid D voltage is stuck at 0 V after engine start. Diagnostic support note: • • • • • • • • • • • • • This is a continuous monitor (CCM).
ON-BOARD DIAGNOSTIC STEP INSPECTION 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 5 6 7 8 9 10 11 12 INSPECT ATX CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect ATX connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.).
ON-BOARD DIAGNOSTIC End Of Sie DTC P0771 A6E567001030W32 DTC P0771 Shift solenoid E stuck OFF • When any of P0731, P0732, and P0734 are not generated, and all conditions below are satisfied. ATF temperature 20 °C {68 °F} or above. Driving in 4GR at D range. Engine run. Turbine speed within 2254,988 rpm. Vehicle speed within 60100 km/h {3762 mph}.
ON-BOARD DIAGNOSTIC STEP INSPECTION 6 CHECK OPERATION OF EACH VALVE AND EACH SPRING • Turn ignition key to OFF. • Remove control valve body. • Disassemble control valve body. • Is each valve operation okay and is return spring okay? (See K34 CONTROL VALVE BODY REMOVAL, K35 CONTROL VALVE BODY INSTALLATION.) (See ATX Workshop Manual FN4A-EL (9999-95FN4A-99).) 7 8 VERIFY TROUBLESHOOTING OF DTC P0771 COMPLETED • Make sure to reconnect all disconnected connectors.
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED • Has FREEZE FRAME PID DATA been recorded? 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY • Check for related Service Bulletins availability. • Is any related repair information available? 3 4 5 6 7 8 CHECK ATF CONDITION • Turn ignition key to OFF. • Check ATF condition.
ON-BOARD DIAGNOSTIC DTC P0773 DTC P0773 DETECTION CONDITION POSSIBLE CAUSE A6E567001030W34 Shift solenoid E malfunction (electrical) • If PCM detects either of following conditions while driving in 4GR at D range with TCC operation, PCM determines that shift solenoid E circuit has a malfunction: Shift solenoid E voltage is stuck at B+ after engine start. Shift solenoid E voltage is stuck at 0 V after engine start.
ON-BOARD DIAGNOSTIC STEP INSPECTION 3 INSPECT ATX CONNECTOR FOR POOR CONNECTION • Turn ignition key to OFF. • Disconnect ATX connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.). • Is connection okay? 4 INSPECT RESISTANCE • Inspect resistance between ATX connector terminal F (transaxle case side) and body ground. • Is resistance within 10.926.2 ohms? (See K26 Resistance Inspection (On-Vehicle Inspection).
ON-BOARD DIAGNOSTIC DTC P0841 A6E567001030W35 DTC P0841 Oil pressure switch circuit malfunction • When each of DTC P0731, P0732, P0733 and P0734 are not generated and 10 seconds or more passed. When all conditions below satisfied while driving in 1GR, 2GR or 3GR. • ATF temperature 20 °C {68 °F} or above. • Oil pressure switch OFF • Revolution ratio of forward clutch drum revolution to differential gear case revolution below 0.91 or more than 3.08.
ON-BOARD DIAGNOSTIC STEP INSPECTION 2 INSPECT OIL PRESSURE SWITCH CONNECTOR FOR POOR CONNECTION • Disconnect shift oil pressure switch connector. • Check for poor connection (damaged/pulledout terminals, corrosion, etc.). • Is connection okay? 3 INSPECT CONTINUITY • inspect for continuity between oil pressure switch terminal A (part-side) and body ground. • Is there any continuity? 4 5 6 7 8 INSPECT PCM CONNECTOR FOR POOR CONNECTION • Disconnect PCM connector.
ON-BOARD DIAGNOSTIC PID/DATA MONITOR AND RECORD function table Monitor item (Definition) Unit/ Condition GEAR LINEDES LPS (Pressure control solenoid) OP SW B (Oil pressure switch) SSA/SS1 (Shift solenoid A) SSB/SS2 (Shift solenoid B) SSC/SS3 (Shift solenoid C) 1GR: 1 2GR: 2 3GR: 3 4GR: 4 kPa Condition/Specification inHg Indicates target line pressure Change current value according to throttle opening angle % ATF 20 °C {68 °F}: 3.43.6 V ATF 130 °C {266 °F}: 0.40.
TROUBLESHOOTING TROUBLESHOOTING FOREWORD A6E568001030W01 • Refer to Section GI and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the procedures. End Of Sie BASIC INSPECTION STEP INSPECTION 1 Perform the mechanical system test. (See K6 MECHANICAL SYSTEM TEST.) Is mechanical system okay? A6E568001030W02 ACTION Yes No 2 Turn IG SW to ON.
TROUBLESHOOTING SYMPTOM TROUBLESHOOTING ITEM TABLE A6E568001030W03 • Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 TROUBLESHOOTING ITEM Vehicle does not move in D, S, L ranges, or in R position DESCRIPTION PAGE Vehicle does not move when AP depressed. (See K117 NO.1 VEHICLE DOES NOT MOVE IN D, S, L RANGES, OR IN R POSITION.) Vehicle moves in N position Vehicle creeps in N position. (See K117 NO.
TROUBLESHOOTING No. 18 TROUBLESHOOTING ITEM Excessive shift shock is given when upshifting and downshifting 19 Excessive shift shock on torque converter clutch (TCC) 20 Noise occurs at idle when vehicle is stopped in all positions/ranges Transaxle is noisy in all positions and ranges when vehicle idling. 21 Noise occurs at idle when vehicle is stopped in D, S, L ranges, or in R position Transaxle is noisy in driving ranges when vehicle idling.
TROUBLESHOOTING QUICK DIAGNOSIS CHART A6E568001030W04 K A6E5680W001 K115
TROUBLESHOOTING A6E5680W002 End Of Sie K116
TROUBLESHOOTING NO.1 VEHICLE DOES NOT MOVE IN D, S, L RANGES, OR IN R POSITION 1 DESCRIPTION POSSIBLE CAUSE A6E568001030W05 Vehicle does not move in D, S, L ranges, or in R position • Vehicle does not move when AP depressed. • If the vehicle does not move in D, S, L ranges or R position, basically, the malfunction is in the ATX. (Vehicle will move even with a malfunction in the PCM.
TROUBLESHOOTING STEP INSPECTION 2 Disconnect PCM. Is resistance between ground terminal at PCM connector and body ground less than 5.0 ohms? 3 Check LPS PID value using WDS or equivalent. Is LPS PID value okay? (See F45 PCM INSPECTION.) Yes No Yes No ACTION Go to next step. Repair open ground circuit. Reconnect PCM. Overhaul control valve body and repair or replace any defective parts. If problem remains, overhaul transaxle and repair or replace any defective parts.
TROUBLESHOOTING STEP INSPECTION 2 Check the value at the following PID using the WDS or equivalent. (See F45 PCM INSPECTION.) • TP Is PID value okay? 3 Disconnect PCM. Is resistance between ground terminal at PCM connector and body ground less than 5.0 ohms? 4 Check LPS PID value. Is LPS PID value okay? (See F45 PCM INSPECTION.) Yes No ACTION Go to next step. Repair or replace any defective parts. Yes No Go to next step. Repair open ground circuit.
TROUBLESHOOTING STEP INSPECTION 3 Disconnect solenoid connector. Does vehicle operate as follows? Yes No D, S ranges: 3GR (fixed) L range: 1GR (fixed) R position: Reverse 4 Drive vehicle in D, S, and L ranges except HOLD mode. Does vehicle start from stop in first gear? Yes No 5 Check the value at the following PIDs using the WDS or equivalent. (See F45 PCM INSPECTION.) • SSA/SS1 • SSB/SS2 • SSC/SS3 Are PID values okay? Yes No 6 Perform the stall test. (See K7 Stall Test.
TROUBLESHOOTING • Basically, TCC does not operate when fail-safe is operating. Verify the DTCs first. If the TCC operates when driving at high speeds only, malfunction (improper adjustment) is in the HOLD switch circuit or TR switch circuit. Caution • If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which may have mixed in with the ATF. POSSIBLE CAUSE 1.
TROUBLESHOOTING NO.9 ABNORMAL SHIFTING 9 DESCRIPTION POSSIBLE CAUSE A6E568001030W13 Abnormal shifting • Shift incorrectly (incorrect shift pattern). • There is a malfunction in the signal circuit which controls shifting (TP sensor, input/turbine speed sensor, vehicle speed sensor), the control valve is stuck, the accumulator (forward or servo apply) is stuck, or the clutch circuit is stuck. 1.
TROUBLESHOOTING NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION 12 DESCRIPTION POSSIBLE CAUSE A6E568001030W16 Torque converter clutch (TCC) non-operation • TCC does not operate when vehicle reaches TCC operation range. • Basically, the TCC does not operate when the fail-safe is operating. Verify the DTC first. Caution • If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which may have mixed in with the ATF. 1.
TROUBLESHOOTING End OfENGINE Sie NO.14 FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING 14 DESCRIPTION POSSIBLE CAUSE A6E568001030W18 Engine flares up or slips when upshifting or downshifting • When accelerator pedal is depressed for driveway, engine speed increases but vehicle speed increases slowly. • When accelerator pedal is depressed while driving, engine speed increases but vehicle does not. • There is clutch slip because clutch is stuck or line pressure is low. 1.
TROUBLESHOOTING NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION 16 DESCRIPTION POSSIBLE CAUSE A6E568001030W20 Judder upon torque converter clutch (TCC) operation • Vehicle jolts when TCC is engaged. • Poor TCC engagement due to either slippage because the TCC is stuck or the line pressure is low Caution • If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which may have mixed in with the ATF. 1.
TROUBLESHOOTING NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE 17 DESCRIPTION POSSIBLE CAUSE A6E568001030W21 Excessive shift shock from N to D or N to R position/range • Strong shock felt when shifting from N to D or N to R position/range. • Shift shock may worsen when the fail-safe is operating. If no DTC is output, the shift shock may worsen due to poor operation of the control valve body or sticking of the clutch. 1.
TROUBLESHOOTING End OfEXCESSIVE Sie NO.18 SHIFT SHOCK IS FELT WHEN UPSHIFTING AND DOWNSHIFTING 18 DESCRIPTION POSSIBLE CAUSE A6E568001030W22 Excessive shift shock is felt when upshifting and downshifting • Excessive shift shock felt when depressing accelerator pedal to accelerate at upshifting. During cruising, excessive shift shock is felt when depressing accelerator pedal at downshifting. • Shift shock may worsen when fail-safe is operating.
TROUBLESHOOTING NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGES 20 DESCRIPTION POSSIBLE CAUSE A6E568001030W24 Noise occurs at idle when vehicle is stopped in all positions/ranges • Transaxle noisy in all positions and ranges when vehicle is idling. • The malfunction is in the oil pump which causes a high-pitched noise to be emitted from the transaxle at idle. Note • If a noise is emitted during shifting only, the malfunction is in shift solenoid D, E or shift solenoid A, B, C.
TROUBLESHOOTING NO.22 NO ENGINE BRAKING IN HOLD MODE 22 DESCRIPTION POSSIBLE CAUSE A6E568001030W26 No engine braking in hold mode • Engine speed drops to idle but vehicle coasts when accelerator pedal is released during cruising at medium to high speeds. • Engine speed drops to idle but vehicle coasts when accelerator pedal is released when in L range at low vehicle speed. 1.
TROUBLESHOOTING STEP 4 5 INSPECTION • Disconnect PCM. • Is resistance between ground terminal at PCM connector and body ground less than 5.0 ohms? • Check LPS PID value. • Is LPS PID value okay? (See F45 PCM INSPECTION.) Yes No Yes No ACTION Go to next step. Repair open ground circuit. Reconnect PCM. Overhaul control valve body and repair or replace any defective parts. If problem remains, overhaul transaxle and repair or replace any defective parts. (See ATX workshop manual (FN4A-EL) [1623-10-98E].
TROUBLESHOOTING Diagnostic procedure STEP 1 2 3 4 INSPECTION • Are other indicator lights illuminated with ignition switch is at ON? • Check the HOLD switch (See K13 HOLD SWITCH INSPECTION.) • Is HOLD switch okay? • Disconnect PCM. • Turn ignition switch on. • Is voltage between 3Q terminal at the PCM connector and body ground greater than 10.5 V? • Check the HOLD indicator light. • Is HOLD indicator light okay? Yes No Yes No ACTION Inspect meter fuse. Go to next step. Go to next step.
FRONT AND REAR AXLES M LOCATION INDEX ................................................ M-2 FRONT AXLE/DRIVE SHAFT LOCATION INDEX........................................... M-2 REAR AXLE LOCATION INDEX......................... M-3 GENERAL PROCEDURES ................................... M-3 PRECAUTION (FRONT AND REAR AXLE) ....... M-3 FRONT AXLE ........................................................ M-4 WHEEL HUB, STEERING KNUCKLE PRE-INSPECTION...........................................
LOCATION INDEX LOCATION INDEX FRONT AXLE/DRIVE SHAFT LOCATION INDEX A6E630004000W01 A6E0612W106 .
LOCATION INDEX, GENERAL PROCEDURES REAR AXLE LOCATION INDEX A6E630005000W01 A6E0312W016 . 1 Wheel hub, hub spindle (See M9 WHEEL HUB, HUB SPINDLE PREINSPECTION) (See M10 WHEEL HUB, HUB SPINDLE REMOVAL/INSTALLATION) End Of Sie M GENERAL PROCEDURES PRECAUTION (FRONT AND REAR AXLE) A6E631001018W01 Wheel and Tire Removal/Installation 1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to 88118 N·m {9.012.
FRONT AXLE FRONT AXLE WHEEL HUB, STEERING KNUCKLE PRE-INSPECTION Wheel Bearing Play Inspection 1. Position a dial indicator against the wheel hub. 2. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. A6E631204000W01 Maximum wheel bearing play 0.05 mm {0.002 in} 3. If the bearing play exceeds the specification, replace and tighten the locknut to the specified torque and retest. • Replace the wheel bearing as necessary.
FRONT AXLE WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION A6E631204000W02 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced. 1. Remove in the order indicated in the table. 2.
FRONT AXLE Locknut Removal Note 1. Knock the crimped portion of the locknut outward using a small chisel and a hammer. 2. Lock the hub by applying the brakes. 3. Remove the locknut. A6E6321W001 Wheel Hub Component Removal Note 1. Remove the wheel hub component using the SSTs. A6E0311W015 2. If the bearing inner race remains on the front wheel hub component, grind a section of the bearing inner race until approx. 0.5 mm {0.02 in} remains. Then remove it using a chisel.
FRONT AXLE Dust Cover Removal Note Note • The dust cover does not need to be removed unless it is being replaced. 1. Mark the dust cover and steering knuckle for proper installation. A6E0311W018 2. Remove the dust cover using a chisel. M A6E0311W019 Hub Bolt Removal Note Note • The hub bolts do not need to be removed unless they are being replaced. 1. Remove the hub bolts using a press. A6E6312W003 Hub Bolt Installation Note 1. Install the new hub bolts using a press.
FRONT AXLE Dust Cover Installation Note 1. Mark the new dust cover in the same way as the removed one. 2. Align the marks of the new dust cover and the knuckle. A6E0312W010 3. Install the new dust cover using the SSTs. A6E0312W011 Wheel Bearing Installation Note 1. Install the new wheel bearing using the SSTs. A6E0312W012 Wheel Hub Component Installation Note 1. Install the wheel hub component using the SSTs.
FRONT AXLE, REAR AXLE Locknut Installation Note 1. Install a new locknut and stake it as shown. A6E0312W015 End Of Sie REAR AXLE WHEEL HUB, HUB SPINDLE PRE-INSPECTION Wheel Bearing Play Inspection 1. Position a dial indicator against the wheel hub. 2. Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play. A6E631405000W01 M Maximum wheel bearing play 0.05 mm {0.002 in} 3.
REAR AXLE WHEEL HUB, HUB SPINDLE REMOVAL/INSTALLATION A6E631405000W02 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (body side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced. 1. Remove in the order indicated in the table. 2.
REAR AXLE ABS Sensor Rotor Removal Note Note • The sensor rotor does not need to be removed unless it is being replaced. 1. Remove the sensor rotor using a chisel. A6E6314W001 ABS Sensor Rotor Installation Note Caution • Position the SST so that marking B faces the bottom. M 1. Set the SST as shown in the figure. A6E0313W011 2. Press on the new sensor rotor using the SST and a press. A6E0313W012 Locknut Installation Note 1. Install a new locknut and stake it as shown.
DRIVE SHAFT End Of Sie DRIVE SHAFT JOINT SHAFT PRE-INSPECTION 1. Verify that the joint shaft is not twisted or cracked. • Replace it as necessary. 2. Turn the joint shaft by hand and verify that the bearing rotates smoothly and freely. • Replace it as necessary.
DRIVE SHAFT 1 2 3 4 5 Tie-rod end ball joint (See N11 Tie-rod End Ball Joint Removal Note) bolt Lower arm (front, rear) ball joint (See R15 FRONT LOWER ARM (FRONT) REMOVAL/INSTALLATION) (See R19 FRONT LOWER ARM (REAR) REMOVAL/INSTALLATION) Stabilizer control link Brake caliper component (See M13 Brake Caliper Component Removal Note) 6 7 8 9 10 Disk plate (See P20 Disc Plate Removal Note) Wheel hub, steering knuckle and drive shaft (See M13 Wheel Hub, Steering Knuckle and Drive Shaft Removal Note)
DRIVE SHAFT Clip Installation Note 1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does not exceed the specification on installation. 2. After installation, measure the outer diameter. If it exceeds the specification, repeat Step 1 using a new clip. Outer diameter specification 31.2 mm {1.23 in} max. A6E0313W021 End Of Sie JOINT SHAFT DISASSEMBLY/ASSEMBLY A6E631625700W03 1. Disassemble in the order indicated in the table. 2.
DRIVE SHAFT Bearing Disassembly Note 1. Remove the bearing using the SSTs. A6E0313W053 Dust Seal (Right) Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the new right side dust seal using the SSTs. M A6E0313W028 Bearing Assembly Note 1. Install the new bearing using the SSTs.
DRIVE SHAFT Dust Seal (Left) Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the new left side dust seal using a steel plate and the SSTs. A6E0313W030 Joint Shaft Assembly Note 1. Assemble the joint shaft using a press and the SST. A6E0313W029 End Of Sie DRIVE SHAFT PRE-INSPECTION 1. Inspect the dust boot on the drive shaft for cracks, damage, leaking grease, and looseness in the boot band. 2. Inspect the drive shaft for bends, cracks, and wear in the joint or splines.
DRIVE SHAFT DRIVE SHAFT REMOVAL/INSTALLATION A6E631625500W02 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced. 1. Drain the transaxle oil (left side).
DRIVE SHAFT Drive Shaft Removal Note 1. Install a spare nut onto the drive shaft so that the nut is flush with the end of the drive shaft. 2. Tap the nut with a copper hammer to loosen the drive shaft from the front wheel hub. 3. Separate the drive shaft from the wheel hub. Caution • The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when removing the drive shaft from the transaxle. A6E6316W001 4.
DRIVE SHAFT Drive Shaft Installation Note Caution • The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the drive shaft to the transaxle. • The oil seals are damaged easily if this procedure is not done correctly. 1. 2. 3. 4. Insert the drive shaft into the wheel hub. Apply transaxle oil to the oil seal lip. Push the drive shaft into the transaxle.
DRIVE SHAFT Boot Band (Wheel Side) Disassembly Note Note • The boot band does not need to be removed unless it is being replaced. 1. Remove the boot clamp with end clamp pliers as shown and discard the clamp. A6E6316W004 Boot Band (Transaxle Side) Disassembly Note 1. Pry up the locking clips using a screwdriver. 2. Pull back the end of the band. A6E6316W005 Outer Ring Disassembly Note 1. Mark the outer ring and the shaft for proper assembly. 2. Remove the outer ring.
DRIVE SHAFT Boot Disassembly Note Note • The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft component. • Do not strip the tape until the boot is assembled. 1. Wrap the shaft splines with tape. 2. Remove the boot. A6E0313W048 ABS Sensor Rotor (With ABS) Disassembly Note M Caution • Do not remove the sensor rotor unless it is necessary. • Do not reuse the sensor rotor if removed. 1. Tap the ABS sensor rotor off the drive shaft using a chisel.
DRIVE SHAFT ABS Sensor Rotor (With ABS) Assembly Note 1. Set a new ABS sensor rotor on the drive shaft and press it on using the SSTs. A6E0313W050 Boot Assembly Note Note • The wheel side and transaxle side boots are different. 1. Fill the boot (wheel side) with the specified grease. Caution • Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot. Grease amount 90110 g {3.183.88 oz} 2.
DRIVE SHAFT 4. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution • Do not let grease leak. • Do not damage the boot. 5. Verify that the drive shaft length is within the standard. A6E6316W007 Boot Band (Transaxle Side) Assembly Note 1. Fold the band in the direction opposite to the forward revolving direction of the drive shaft and use pliers to pull it tight. 2. Lock the end of the band by bending the locking clips.
DRIVE SHAFT 6. Crimp the wheel side big boot band using the SST. 7. Verify that clearance B is within the specification. • If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again. • If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and crimp the new boot. Clearance B 2.42.8 mm {0.0950.110 in} 8. Verify that the boot band does not protrude from the boot band installation area.
DRIVE SHAFT 1 2 3 4 5 6 Boot band (wheel side) (See M20 Boot Band (Wheel Side) Disassembly Note) (See M23 Boot Band (Wheel Side) Assembly Note) Boot band (transaxle side) See M20 Boot Band (Transaxle Side) Disassembly Note See M23 Boot Band (Transaxle Side) Assembly Note Clip See M25 Clip Disassembly Note See M26 Outer Ring, Clip Assembly Note Outer ring (See M26 Outer Ring, Clip Assembly Note) Snap ring (See M26 Cage, Inner Ring, Balls, Snap Ring Assembly Note) Balls (See M25 Balls, Inner Ring,
DRIVE SHAFT Dynamic Damper Assembly Note 1. Install the dynamic damper as shown in the figure. Standard length 334.7340.7 mm {13.213.4 in} 2. Install the new boot band onto the dynamic damper. A6E6316W006 Boot Assembly Note Note • The wheel side and transaxle side boots are different. 1. Fill the boot (wheel side) with the specified grease. Caution • Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot. Grease amount 90110 g {3.183.
DRIVE SHAFT Standard length L8, LF L3 Left side 677.7687.7 {26.6927.07} 676.6686.6 {26.6427.03} mm {in} Right side 628.6638.6 {24.7525.14} 6. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution • Be careful not to allow the grease to leak. • Do not damage the boot. 7. Verify that the drive shaft length is within the specification.
STEERING SYSTEM N LOCATION INDEX .................................................N-2 STEERING LOCATION INDEX ...........................N-2 GENERAL PROCEDURES ....................................N-3 PRECAUTION (STEERING)................................N-3 ENGINE SPEED SENSING POWER STEERING ..............................................................N-3 AIR BLEEDING ....................................................N-3 POWER STEERING FLUID INSPECTION..........
LOCATION INDEX LOCATION INDEX STEERING LOCATION INDEX A6E660001036W01 A6E0610W010 .
GENERAL PROCEDURES , ENGINE SPEED SENSING POWER STEERING GENERAL PROCEDURES PRECAUTION (STEERING) A6E661001036W01 Wheels and Tires Removal/Installation 1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to 88118 N·m {9.012.0 kgf·m, 65.087.0 ft·lbf}. Power Steering Components Removal/Installation 1. If any power steering fluid line has been disconnected anytime during the procedure, add ATF M-III or equivalent (e.g.
ENGINE SPEED SENSING POWER STEERING POWER STEERING FLUID INSPECTION Fluid Level Inspection 1. Inspect the power steering fluid level. • Add fluid to the specified level as necessary. A6E661432040W01 Fluid specification ATF M-III or equivalent (e.g. Dexron®II) Fluid Leakage Inspection 1. Start the engine and let it idle. 2. Turn the steering wheel fully to the left and right to apply fluid pressure.
ENGINE SPEED SENSING POWER STEERING 6. Close the gauge valve completely. 7. Increase the engine speed to 1,0001,500 rpm and measure the fluid pressure generated by the oil pump. • If the pressure is not within the specification, repair or replace the oil pump component. Caution • If the valve is left closed for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump. A6E0612W081 Oil pump fluid pressure 10.8011.29 MPa {110.2115.2 kgf/cm2, 15671637 psi} 8.
ENGINE SPEED SENSING POWER STEERING STEERING WHEEL AND COLUMN INSPECTION A6E661432010W01 Steering Wheel Play Inspection 1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that the play is within the specification. • If the play exceeds the specification, either the steering joints are worn or the backlash of the steering gear is excessive. Correct as necessary. Play 030 mm {01.18 in} Steering Wheel Looseness Inspection 1.
ENGINE SPEED SENSING POWER STEERING STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION A6E661432010W02 Warning • Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See T117 SERVICE WARNINGS.) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. N A6E0612W017 1 2 3 4 5 6 .
ENGINE SPEED SENSING POWER STEERING Steering Wheel Removal Note Caution • Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse. 1. Set the vehicle in the straight-ahead position. 2. Remove the steering wheel using a suitable puller. Steering Lock Mounting Bolts Removal Note 1. Make a groove in the heads of the steering lock mounting bolts using a chisel and a hammer. 2. Remove the bolts using a screwdriver. 3. Disassemble the steering lock component.
ENGINE SPEED SENSING POWER STEERING STEERING SHAFT INSPECTION 1. Inspect the following. (1) Column bearing for damage (2) Steering shaft length • Replace the steering shaft component as necessary. A6E661432100W01 Length 211.6 mm {8.3 in} A6E0612W022 2. Inspect the tilt and telescope operation (1) Verify that the adjusting lever moves smoothly from unlock position to lock position. (2) Verify that the steering shaft is fixed firmly when the adjusting lever is locked.
ENGINE SPEED SENSING POWER STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION A6E661432960W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle. 1.
ENGINE SPEED SENSING POWER STEERING Bolt (Intermediate Shaft) Removal Note 1. Mark the pinion shaft and gear housing for proper installation. A6E0612W084 Tie-rod End Ball Joint Removal Note 1. Remove the tie rod-nut. 2. Separate the tie-rod end from the steering knuckle using the SSTs. N A6E0612W085 Steering Gear and Linkage Removal Note L.H.D. Caution • Excessively loosening the crossmember nuts may possibly cause the crossmember to fall off.
ENGINE SPEED SENSING POWER STEERING Steering Gear and Linkage Installation Note 1. Loosely tighten bolts. 2. Tighten the mounting bracket bolts to the specified torque in the order shown. Tightening torque 74.4104.8 N·m {7.610.6 kgf·m, 5577 ft·lbf} 3. Tighten the crossmember installation nuts. (L.H.D.) Tightening torque Nut: 119.6154.8 N·m {12.215.7 kgf·m, 89114 ft·lbf} Bolt: 93.1131.3 N·m {9.513.3 kgf·m, 6996 ft·lbf} A6E0612W027 Bolt (Intermediate Shaft) Installation Note 1.
ENGINE SPEED SENSING POWER STEERING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Oil pipe Tie-rod end Locknut Boot clamp Boot band Boot Tie rod (See N13 Tie Rod Disassembly Note) Washer Locknut (adjusting cover) (See N13 Locknut (Adjusting Cover) Disassembly Note) Adjusting cover (See N14 Adjusting Cover Disassembly Note) Yoke spring Support yoke Bolt Pinion shaft and housing component (See N14 Pinion Shaft and Housing Component Disassembly Note) Pinion shaft component (See N14 Pinion Shaft Component
ENGINE SPEED SENSING POWER STEERING Adjusting Cover Disassembly Note 1. Remove the adjusting cover. A6E0612W033 Pinion Shaft and Housing Component Disassembly Note 1. Hold the pinion shaft as shown, and pull out the pinion shaft and housing component. A6E0612W038 Pinion Shaft Component Disassembly Note Note • If the pinion shaft does not come out easily, remove it using a press. 1. Push out the pinion shaft componet from the valve housing as shown. A6E0612W034 Snap Ring Disassembly Note 1.
ENGINE SPEED SENSING POWER STEERING Upper Bearing, Oil Seal Disassembly Note 1. Set the SST as shown. 2. Using a press, remove the oil seal and upper bearing without applying pressure to the edge of the valve housing. A6E0612W035 Holder Disassembly Note 1. Cut away the staked area by using a drill. Caution • Carefully pull out the holder without damaging the U gasket. 2. Disassemble the holder. N A6E0612W037 Oil Seal, Inner Guide Disassembly Note 1. Set the SSTs into the valve side. 2.
ENGINE SPEED SENSING POWER STEERING STEERING GEAR AND LINKAGE INSPECTION Rack Inspection 1. Inspect the rack for cracking, damage, and tooth wear. Replace it as necessary. 2. Measure the runout of the rack. A6E661432960W03 Runout Near point A: 0.15 mm {0.006 in} max. Near point B: 0.20 mm {0.008 in} max. 3. If not within the specification, replace the rack. A6E0612W041 Tie-rod End Inspection 1. Inspect the tie-rod end for damage and boot cracks. Replace it as necessary. 2.
ENGINE SPEED SENSING POWER STEERING 1. Assemble in the order indicated in the table. .
ENGINE SPEED SENSING POWER STEERING Mounting Rubber Assembly Note 1. Apply soapy water to the rubber part of the mounting rubber. 2. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press. A6E0612W087 3. Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes out completely from the other side. At this time, mounting rubber end and steel pipe are aligned.
ENGINE SPEED SENSING POWER STEERING 5. Using the SST, place the oil seal and inner guide at the edge of the steering racks pinion, and remove the SST. A6E0612W049 6. After installing the steering rack to the gear housing, press the oil seal and inner guide using the SSTs until the force required suddenly increases. N A6E0612W039 Holder Assembly Note 1. Apply grease to the U-gasket and O-ring. 2. Assemble the U-gasket, backup ring and O-ring into the holder. 3. Assemble the SST to the steering rack.
ENGINE SPEED SENSING POWER STEERING Oil Seal Assembly Note 1. Apply grease to a new oil seal. 2. Press in the new oil seal using the SSTs. A6E0612W036 Upper Bearing Assembly Note 1. Apply grease to a new upper bearing. 2. Press in the upper bearing using the SST. A6E0612W051 Seal Ring Assembly Note 1. Install a new seal ring to the valve part of the pinion shaft using the SST. 2. After installing it, seat it properly using the SST. 3. Install the snap ring. A6E0612W052 Adjusting Cover Assembly Note 1.
ENGINE SPEED SENSING POWER STEERING 5. Measure the pinion torque using the SST and a pull scale. Standard Center of rack ±90°° 0.81.2 N·m {8.212.2 kgf·cm, 5.88.8 in·lbf} [Pull scale reading 812 N {0.91.2 kgf, 1.82.6 lbf}] Except center of rack ±90°° Less than 1.6 N·m {16.3 kgf·cm, 11.8 in·lbf} [Pull scale reading Less than 16.7 N {1.7 kgf, 3.8 lbf}] A6E0612W042 6. If not as specified, repeat steps 2 through 5. 7. Install the locknut using the SST (49 B032 320). Tightening torque 4049 N·m {4.14.
ENGINE SPEED SENSING POWER STEERING POWER STEERING OIL PUMP REMOVAL/INSTALLATION A6E661432650W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. . A6E0612W092 1 2 3 Drive belt Pressure switch connector Pressure pipe 4 5 Suction hose Power steering oil pump End Of Sie POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY A6E661432650W02 Note • The following procedure is for replacement of the O-ring and oil seal only.
ENGINE SPEED SENSING POWER STEERING N A6E0612W068 .
ENGINE SPEED SENSING POWER STEERING Power Steering Oil Pump Component Disassembly Note 1. Secure the power pressure oil pump using the SST. Caution • Use the SST to prevent damage to the pump when securing it in a vise. Clip Disassembly Note 1. Lift up the clip tab using a flathead screwdriver. 2. Remove the clip pushing with a flathead screwdriver and a hammer as shown in the figure. Clip Assembly Note 1. Push the clip slowly to the direction shown in the figure. 2.
ENGINE SPEED SENSING POWER STEERING Oil Seal Assembly Note 1. Install the oil seal in the front pump body using the SST and plastic hammer. A6J6612W100 Vane Assembly Note 1. Place the vanes in the rotor with the rounded edges contacting the cam. N A6E6316W013 Cam Ring Assembly Note 1. Install the cam ring in the front pump body with the mark facing upward. A6E6316W014 Rear Pump Body Assembly Note 1. After installing the rear body, manually turn the shaft to verify that it rotates smoothly.
BRAKING SYSTEM P LOCATION INDEX ................................................. P-3 CONVENTIONAL BRAKE LOCATION INDEX ... P-3 PARKING BRAKE LOCATION INDEX ................ P-4 ABS/TCS LOCATION INDEX .............................. P-4 DSC LOCATION INDEX ...................................... P-5 GENERAL PROCEDURES .................................... P-6 PRECAUTION (BRAKES) ................................... P-6 CONVENTIONAL BRAKE SYSTEM...................... P-6 AIR BLEEDING ...........................
DTC C1414 ........................................................P-91 DTC C1507, C1508............................................P-91 DTC C1510, C1511, C1512, C1513 ..................P-92 DTC C1953, C1954............................................P-92 DTC C1955, C1956............................................P-93 DTC U2021 ........................................................P-96 TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) ....P-97 SYSTEM WIRING DIAGRAM ............................
LOCATION INDEX LOCATION INDEX CONVENTIONAL BRAKE LOCATION INDEX A6E690001015W01 P A6E6900W001 .
LOCATION INDEX PARKING BRAKE LOCATION INDEX A6E690001015W02 A6E6900W005 . 1 Parking bake lever (SeeP26 PARKING BRAKE (LEVER TYPE) INSPECTION) (SeeP26 PARKING BRAKE (LEVER TYPE) ADJUSTMENT) (SeeP26 PARKING BRAKE (LEVER TYPE) REMOVAL/INSTALLATION) ABS/TCS LOCATION INDEX End Of Sie A6E690001015W03 A6E6900W003 .
LOCATION INDEX 3 4 Rear ABS wheel-speed sensor (SeeP34 REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION) TCS OFF switch (SeeP31 TCS (DSC) OFF SWITCH REMOVAL/ INSTALLATION) (SeeP32 TCS (DSC) OFF SWITCH INSPECTION) 5 6 L.H.D. R.H.D. End Of Sie DSC LOCATION INDEX A6E690001015W04 P A6E6900W004 .
GENERAL PROCEDURES, CONVENTIONAL BRAKE SYSTEM GENERAL PROCEDURES PRECAUTION (BRAKES) A6E691001020W01 Wheels and Tires Removal/Installation 1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to 88118 N·m {9.012.0 kgf·m, 65.087.0 ft·lbf}. Brake Lines Disconnection/Connection Caution • Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off immediately. 1.
CONVENTIONAL BRAKE SYSTEM 4. A second person should loosen the bleeder screw, drain out the fluid and close the screw using the SST. Tightening torque Front:6.99.8 N·m {7199 kgf·cm, 6286 in·lbf} Rear:5.98.8 N·m {6189 kgf·cm, 5377 in·lbf} 5. Repeat steps 3 and 4 until no air bubbles are seen. 6. Bleed air from each component by following the procedure above. 7.
CONVENTIONAL BRAKE SYSTEM Brake Pedal Play Inspection 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Remove the spring pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin. (See P9 BRAKE PEDAL REMOVAL/INSTALLATION.) 3. Gently depress the pedal by hand until resistance is felt, and check the pedal play. Pedal play 03 mm {00.1 in} Brake Pedal Play Adjustment 1. Remove the spring pin and clevis pin. (See P9 BRAKE PEDAL REMOVAL/INSTALLATION.
CONVENTIONAL BRAKE SYSTEM BRAKE PEDAL REMOVAL/INSTALLATION 1. For ATX model, remove the lock unit with brake switch (R.H.D. only). 2. Remove in the order indicated in the table. 1 2 3 4 5 6 A6E691243300W02 Brake switch connector Spring pin Clevis pin Brake pedal Brake switch (See P9 Brake switch Installation Note) Pedal pad 3. Install in the reverse order of removal. A6E6912W020 Brake switch Installation Note 1. Fix the brake switch on a bracket with pressing down at 50 N {5.1 kgf·m, 37 ft·lbf}. 2.
CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. R.H.D. A6E691243400W01 A6E6912W028 L.H.D. A6E6912W018 1 2 3 4 5 Brake fluid level sensor connector Brake pipe Hose (MTX) Master cylinder (See P11 Master Cylinder Installation Note O-ring 2. Install in the reverse order of removal.
CONVENTIONAL BRAKE SYSTEM Master Cylinder Installation Note Caution • Always install the gasket of the power brake unit push rod before performing measurement inspections or adjustments. 1. Install the SST to the power brake unit as shown, and tighten within the specified torque. Tightening torque 9.816.0 N·m {100163 kgf·cm, 87141 in·lbf} A6E6912W042 2. Using a vacuum gauge, create a vacuum pressure of 66.7 kPa {500 mmHg, 19.7 inHg} in the power brake unit. 3.
CONVENTIONAL BRAKE SYSTEM 6. Install the master cylinder to the power brake unit. Caution • If after installing the master cylinder, air does not bleed properly from the brake lines even after performing air bleeding, brake drag occurs or other characteristics are present, it is possible that the master cylinder piston is jammed against the power brake unit. If air cannot be bled properly, brake drag exists or other malfunctions occur, remove the master cylinder and reinstall properly.
CONVENTIONAL BRAKE SYSTEM 3 4 5 6 7 8 9 Reservoir Joint bushing Snap ring Piston guide Cup Stopper Primary piston 10 11 12 13 Stop pin and O-ring (with ABS) (See P13 Stop Pin and O-ring (with ABS) Assembly Note) Stop screw and O-ring (without ABS) (SeeP13 Stop Screw and O-ring (without ABS) Assembly Note) Secondary piston Master cylinder body Stop Screw and O-ring (without ABS) Assembly Note 1. Install the secondary piston and primary piston. 2. Install the new O-ring onto the stop screw. 3.
CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 1 2 3 4 5 6 7 8 A6E691243800W02 Remove the master cylinder. (See P10 MASTER CYLINDER REMOVAL/INSTALLATION.) Remove the wiper arm. (See T57 WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.) Remove the cowl grille. (See S50 COWL GRILLE REMOVAL/INSTALLATION.) Remove the wiper motor. (See T56 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.) Remove the cowl panel. (See S119 COWL PANEL REMOVAL/INSTALLATION.
CONVENTIONAL BRAKE SYSTEM Power Brake Unit Function Check (Inspection Using The Testers) 1. Connect the SSTs, vacuum gauge, and pedal depression force gauge as shown in the figure to bleed the air from SSTs and brake line. (Bleed the air from SSTs using a air bleed valve A.) A6E6912W005 Checking for vacuum loss (unloaded condition) 1. Stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 2. Observe the vacuum gauge for 15 seconds. • If the gauge shows 63.366.
CONVENTIONAL BRAKE SYSTEM DUAL PROPORTIONING VALVE INSPECTION (WITHOUT ABS) 1. Connect the SSTs to the brake pipes as shown in the figure. 2. Bleed the air from the brake system. 3. Measure the fluid pressure of the master cylinder and the rear brake. • If not within the specification, replace the dual proportioning valve.
CONVENTIONAL BRAKE SYSTEM Dual Proportioning Valve Installation Note 1. Install the dual proportioning valve so that the R mark faces the left side of the vehicle. A6E6912W045 FRONT BRAKE (DISC) INSPECTION End Of Sie Brake Judder Repair Hint Description 1. Brake judder concern has the following 3 characteristics: A6E691233980W01 Steering wheel vibration 1. Steering wheel vibrates in the direction of its rotation.
CONVENTIONAL BRAKE SYSTEM Inspection and repair procedure A6E6912W008 Lateral runout inspection 1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10 mm {0.39 in}, inner diameter more than 12 mm {0.47 in}) between the hub bolt and the hub nut. Note • The component parts of the SST (49 B017 001 or 49 G019 003) can be used as a suitable washer. 2.
CONVENTIONAL BRAKE SYSTEM Thickness variation inspection 1. Clean the disc plate-to-pad friction surface using a brake cleaner. 2. Measure the points indicated in the illustration using a caliper (micrometer). 3. Subtract the minimum value from the maximum, and if the result is not within specification, machine the disc plate using a lathe. Thickness variation limit 0.015 mm {0.00059 in} Warning • Do not exceed minimum disc plate thickness.
CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION A6E691233980W02 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag. A6E6912W021 .
CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2. Install the disc pad. A6E6912W038 DISC PAD (FRONT) REPLACEMENT End Of Sie A6E691233630W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. P A6E6912W022 .
CONVENTIONAL BRAKE SYSTEM CALIPER (FRONT) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 1 2 3 4 5 6 7 A6E691233990W01 Dust seal Piston (See P22 Piston Disassembly Note) Piston seal (See P22 Piston Seal Disassembly Note) Bleeder cap Bleeder screw (See P23 Bleeder Screw Assembly Note) Caliper body Boot 2. Assemble in the reverse order of removal. A6E6912W046 Piston Disassembly Note Caution • Blow the compressed air slowly to prevent the piston from suddenly popping out. 1.
CONVENTIONAL BRAKE SYSTEM Bleeder Screw Assembly Note 1. Assemble the bleeder screw to the caliper using the SST. Tightening torque 6.99.8 N·m {7199 kgf·cm, 6286 in·lbf} A6E6912W049 REAR BRAKE (DISC) INSPECTION End Of Sie Brake Judder Repair Hint 1. (See P17 FRONT BRAKE (DISC) INSPECTION.) A6E691226980W01 Disc Plate Thickness Inspection Caution • Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine the disc plate while installed on the vehicle. P 1.
CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DISC) REMOVAL/INSTALLATION A6E691226980W02 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal several times, rotate the wheel by hand, and verify that the brake does not drag. A6E6912W026 .
CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1. Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston inward. (Turn until it stops.) 2. Install the disc pads. 3. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate. Turn the manual adjustment gear back 1/3-turn. A6E6912W039 DISC PAD (REAR) REPLACEMENT End Of Sie A6E691226630W01 1. Remove in the order indicated in the table. 2.
PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PARKING BRAKE (LEVER TYPE) INSPECTION A6E691444000W01 1. Pull the parking brake lever a few times. 2. Depress the brake pedal a few times. 3. Inspect the parking brake stroke by pulling the parking brake lever with a force of 98 N {10 kgf, 22 lbf}. Stroke 36 notches End Of SieBRAKE (LEVER TYPE) ADJUSTMENT PARKING 1. 2. 3. 4. 5. A6E691444000W02 Start the engine and depress the brake pedal several times. Stop the engine.
ABS/TCS ABS/TCS ABS (ABS/TCS) HU/CM SYSTEM INSPECTION A6E692143780W01 System Inspection Preparation 1. Verify that the battery is fully charged. With the ignition switch on, verify that the ABS and BRAKE system warning lights goes out after 2.4 seconds. 2. If the lights stays on after 2.4 seconds, the ABS (ABS/TCS) HU/CM detects a failure. Follow the troubleshooting procedures. 3. Turn the ignition switch off. 4. On level ground, jack up the vehicle and support it evenly on safety stands.
ABS/TCS ABS (ABS/TCS) HU/CM REMOVAL/INSTALLATION A6E692143700W01 Caution • When replacing the ABS (ABS/TCS) HU/CM, configuration procedure must be done before removing the ABS (ABS/TCS) HU/CM. If configuration is not completed before removing the ABS (ABS/TCS) HU/CM, TCS will not work properly (with TCS model). • Do not drop the ABS (ABS/TCS) HU/CM. Replace it if it is subjected to an impact. 1. Configurate the ABS (ABS/TCS) HU/CM (when only replacing it).
ABS/TCS Connector Removal Note 1. Pull the lock lever up and make it unlock. 2. Remove the connector. A6E6916W006 ABS HU/CM Removal/Installation Note 1. When removing/installing the ABS HU/CM from/to the vehicle, attach a strip of protective tape on the ABS HU/ CM connector to prevent brake fluid from entering. Connector Installation Note 1. Verify that the lock lever of the harness connector is completely pulled up. P A6E6916W007 ABS (ABS/TCS) OR DSC HU/CM CONFIGURATION End Of Sie 1.
ABS/TCS Terminal Voltage Table (Reference) (Engine is idling, and connector is connected unless otherwise indicated.
ABS/TCS Terminal Signal Connected to Y Brake switch Brake switch Z Power supply Power supply (Solenoid valve) Power supply (ABS motor) Ground Ground Ignition switch AA AB AC AD Test condition Brake pedal is depressed Brake pedal is released Voltage (V) 1014 Below 0.
ABS/TCS TCS (DSC) OFF SWITCH INSPECTION A6E692167650W03 1. Remove the TCS OFF switch. 2. Inspect for continuity between the TCS OFF switch terminals using an ohmmeter. A6E6921W010 A6E6921W009 • If not within the specification, replace the TCS OFF switch. FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION End Of Sie 1. Remove the mud guard. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. A6E692143720W01 .
ABS/TCS FRONT/REAR ABS WHEEL-SPEED SENSOR INSPECTION End Of Sie A6E692143720W02 Visual Inspection 1. Remove the wheel and tire, and inspect the sensor for looseness and damage. Replace the sensor if necessary. Clearance Inspection 1. Inspect the clearance between the wheel-speed sensor and the sensor rotor. Clearance 0.31.1 mm {0.0120.043 in} A6E6921W003 Resistance Inspection 1. Disconnect the ABS wheel-speed sensor connector. 2. Inspect the resistance at the ABS wheel-speed sensor.
ABS/TCS REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION 1. Remove the tire house trim.S91 TIRE HOUSE TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. A6E692143710W01 A6E6916W002 .
DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL DSC SYSTEM INSPECTION Preparation 1. Verify that the battery is fully charged. 2. With ignition switch on, verify that the ABS warning light goes out after 2.4 seconds. 3. Turn the ignition switch off. 4. On level ground, jack up the vehicle and support it evenly on safety stands. 5. Shift the transaxle to N position. 6. Release the parking brake. 7. Rotate the wheels by hand, and inspect for brake drag. A6E692067650W01 Operation of DSC Inspection 1.
DYNAMIC STABILITY CONTROL Pressure reduction Command name LF_TC_VLV RF_TC_VLV LF_DSC_V RF_DSC_V ABS_POWER LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET RR_INLET RR_OUTLET PMP_MOTOR Wheels LF RF LR RR OFF ON ON OFF OFF ON OFF OFF ON OFF OFF ON ON Note • To protect the DSC HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10 seconds each time they are switched on. 4.
DYNAMIC STABILITY CONTROL Pressure retention Command name LF_TC_VLV RF_TC_VLV LF_DSC_V RF_DSC_V ABS_POWER LF_INLET LF_OUTLET LR_INLET LR_OUTLET RF_INLET RF_OUTLET RR_INLET RR_OUTLET PMP_MOTOR Wheels Inhibition of understeer tendency Inhibition of oversteer tendency control control LF RF LR RR ON OFF ON OFF ON OFF OFF ON ON OFF OFF OFF ON ON OFF OFF ON OFF OFF ON Note • To protect the DSC HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10 seconds each time they are switc
DYNAMIC STABILITY CONTROL DSC HU/CM REMOVAL/INSTALLATION A6E692067650W03 Caution • When replacing the DSC HU/CM, configuration procedure must be done before removing the DSC HU/CM. If configuration is not completed before removing the DSC HU/CM, DTC B2477 will be detected. • Do not drop the DSC HU/CM. Replace it if it is subjected to an impact. 1. Configurate the DSC HU/CM (when only replacing it).(See P29 ABS (ABS/TCS) or DSC HU/CM CONFIGURATION.) 2.
DYNAMIC STABILITY CONTROL Connector Removal Note 1. Rotate the lock lever 40° to the direction A, then push the lock lever to the direction B. Caution • After rotated the lever 40°° , do not push the lock lever to the direction C. The lock lever will be damaged. 2. Verify that the lock lever is completely returned. 3. Remove the harness side connector to the direction D. A6E6920W011 DSC HU/CM and Bracket Removal/Installation Note 1.
DYNAMIC STABILITY CONTROL DSC HU/CM INSPECTION 1. 2. 3. 4. Remove the battery and battery bracket. Disconnect the DSC HU/CM connector. Connect the SST (49 G066 004) to the DSC HU/CM connector and harness side connector. Inspect voltage referring the table below. A6E692067650W04 Terminal Voltage Table (reference value) (Ignition switch is at ON, and connector is connected unless indicated otherwise.
DYNAMIC STABILITY CONTROL Terminal S Signal Combine sensor Connected to Combine sensor Test condition Voltage (V) 3.55.
DYNAMIC STABILITY CONTROL Wheel speed • DSC HU/CM terminal: RF : M ( + ) I ( - ) RR : K ( + ) H ( - ) LF : F ( + ) J ( - ) LR : Q ( + ) N ( - ) • Oscilloscope setting: 1 V/DIV (Y), 2 ms/DIV (X), AC range • Vehicle condition: Driving 30 km/h (18.6 mph) Note • As vehicle speed increases, period of wave shortens. • If there is malfunctioning in the sensor rotor, wave profile warps.
DYNAMIC STABILITY CONTROL COMBINE SENSOR INSPECTION A6E692067650W06 Caution • Be careful and do not allow the lateral-G sensor to fall. If by chance it is subjected to strong impact, replace it. 1. Connect the connector. 2. Turn ignition switch on, verify the voltage between terminals B and E under the following conditions. • If not within the specification, replace the lateral-G sensor. (1) Lateral-G 1) Horizontal Voltage 2.42.6 V A6E6920W008 2) Facing up (inclined 90° from horizontal) Voltage 3.33.
DYNAMIC STABILITY CONTROL 2) Measure voltage at output terminal D and ground terminal E when the yaw rate sensor is rotated left and right. Caution • Be careful when turning the yaw rate sensor rotation position while it is in a reversed state because the rotation direction and voltage will be reversed. Voltage Right rotation: fluctuation between 2.54.62 V Left rotation: fluctuation between 2.50.33 V COMBINE SENSOR INITIALIZATION PROCEDURE A6E6920W005 End Of Sie 1.
ON-BOARD DIAGNOSTIC (ABS/TCS) ON-BOARD DIAGNOSTIC (ABS/TCS) ABS (ABS/TCS) SYSTEM WIRING DIAGRAM A6E697567650W01 P A6E6921T001 .
ON-BOARD DIAGNOSTIC (ABS/TCS) ABS (ABS/TCS) ON-BOARD DIAGNOSIS End Of Sie A6E697567650W02 On-Board Diagnostic (OBD) Test Description • The OBD test inspects the integrity and function of the ABS (ABS/TCS) and outputs the results when requested by the specific tests. • On-board diagnostic test also: Provides a quick inspection of the ABS (ABS/TCS) usually performed at the start of each diagnostic procedure. Provides verification after repairs to ensure that no other faults occurred during service.
ON-BOARD DIAGNOSTIC (ABS/TCS) Active Command Modes Procedure Note • When driving, the ABS motor and each valve forcibly turn ABS_VOLT on, and then each command on. ABS_VOLT regulates the power supply for the ABS motor and 8 valves. 1. Connect WDS or equivalent to the vehicle DLC-2 16-pin connector. 2. Turn the ignition switch to ON (Engine OFF) or start engine. 3. Activate active command modes using WDS or equivalent.
ON-BOARD DIAGNOSTIC (ABS/TCS) DTC WDS or equivalent C1246 Diagnosis system component Right rear pressure reduction solenoid valve C1250 Left rear pressure retention solenoid valve C1254 Right rear ABS pressure retention solenoid valve C1266 Fail-safe relay C1414 C1508 C1510 ABS (ABS/TCS) HU/CM ABS/TCS HU/CM Right front solenoid valve, motor or wheel-speed sensor/sensor rotor Left front solenoid valve, motor or wheel-speed sensor/ sensor rotor Right rear solenoid valve, motor or wheel-speed sensor/s
ON-BOARD DIAGNOSTIC (ABS/TCS) PID Name (Definition) ABSLR_O (Left rear ABS pressure reduction solenoid valve output state) ABSRF_O (Right front ABS pressure reduction solenoid valve output state) ABSLF_O (Left front ABS pressure reduction solenoid valve output state) ABSRR_I (Right rear ABS pressure reduction solenoid valve output state) ABSLR_I (Left rear ABS pressure retention solenoid valve output state) ABSRF_I (Right front ABS pressure retention solenoid valve output state) ABSLF_I (Left front A
ON-BOARD DIAGNOSTIC (ABS/TCS) PID Name (Definition) Unit/Condition RF_WSPD (Right front wheel-speed sensor input) KPH or MPH LR_WSPD (Left rear wheel-speed sensor input) KPH or MPH RR_WSPD (Right rear wheel-speed sensor input) KPH or MPH ABS_VOLT (System battery voltage value) V Condition/Specification • Vehicle is stopped: 0 KPH {0 MPH} • Vehicle is driving: Indicates vehicle speed • Vehicle is stopped: 0 KPH {0 MPH} • Vehicle is driving: Indicates vehicle speed • Vehicle is stopped: 0 KPH {0 MPH
ON-BOARD DIAGNOSTIC (ABS/TCS) P Diagnostic procedure STEP INSPECTION 1 INSPECT BATTERY VOLTAGE • Is battery terminal voltage okay? 2 INSPECT BATTERY GRAVITY • Is battery specific gravity as specified? 3 INSPECT CHARGING SYSTEM • Are generator and drive belt tension okay? 4 INSPECT ABS (ABS/TCS) HU/CM POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Start engine. • Measure voltage between ABS (ABS/TCS) HU/CM terminal Z and ground.
ON-BOARD DIAGNOSTIC (ABS/TCS) DTC B1342 End Of Sie A6E697567650W04 Caution • When attaching the tester lead to the ABS (ABS/TCS) HU/CM harness connector, the SST (49 G066 001) must be used. (See P29 ABS (ABS/TCS) HU/CM INSPECTION.) DTC B1342 DETECTION CONDITION POSSIBLE CAUSE ABS (ABS/TCS) HU/CM The on-board diagnostic function detects control module malfunction. • Malfunction of ABS (ABS/TCS) HU/CM Diagnostic procedure STEP INSPECTION 1 VERIFY CURRENT STATUS OF MALFUNCTION • Clear DTC from memory.
ON-BOARD DIAGNOSTIC (ABS/TCS) P Diagnostic procedure STEP INSPECTION 1 VERIFY OTHER DTC HAS BEEN RECORDED • If any of DTC C1186 and/or C1266 has also been stored? 2 INSPECT ABS FUSE CONDITION • Is ABS fuse (60 A) okay? 3 4 INSPECT MOTOR RELAY POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect ABS (ABS/TCS) HU/CM connector. • Connect SST (adapter harness) to ABS (ABS/TCS) HU/CM connector (harness side only). • Turn ignition key to ON (engine OFF).
ON-BOARD DIAGNOSTIC (ABS/TCS) STEP INSPECTION 5 VERIFY PUMP MOTOR OPERATION • Turn ignition key to OFF. • Remove SST (adapter harness) and connect all disconnected connectors. • Connect WDS or equivalent to DLC-2. • Turn ignition key to ON (engine OFF). • Access ABS_POWER and PMP_MOTOR active command modes using WDS or equivalent. • Does pump motor operate? 6 VERIFY TROUBLESHOOTING COMPLETED • Clear DTC from memory. (See P46 Clearing DTCs Procedures) • Start engine and drive vehicle at 10 km/h {6.
ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION 1 CHECK FOR CAN FOR DTCs • If any of DTC U1900 and/or U2516 has also been stored? 2 3 4 CHECK FOR PCM FOR DTCs • Turn ignition key to OFF. • Connect WDS or equivalent to DLC-2 • Turn ignition key to ON (engine OFF). • Is DTC for engine control system obtained? VERIFY TROUBLESHOOTING COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory. (See P46 Clearing DTCs Procedures • Start engine.
ON-BOARD DIAGNOSTIC (ABS/TCS) DTC C1145, C1155, C1165, C1175 End Of Sie A6E697567650W10 Caution • When attaching the tester lead to the ABS (ABS/TCS) HU/CM harness connector, the SST (49 G066 001) must be used. (See P29 ABS (ABS/TCS) HU/CM INSPECTION.) C1145 C1155 DTC C1165 C1175 DETECTION CONDITION POSSIBLE CAUSE P56 RF wheel-speed sensor LF wheel-speed sensor RR wheel-speed sensor LR wheel-speed sensor • Abnormal input is detected.
ON-BOARD DIAGNOSTIC (ABS/TCS) P P57
ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION 1 INSPECT WHEEL-SPEED SENSOR CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect ABS (ABS/TCS) HU/CM connector. • Measure resistance between suspected sensor terminals of ABS (ABS/TCS) HU/CM connector (harness side). RF wheel-speed sensor: GD LF wheel-speed sensor: IE RR wheel-speed sensor: AB LR wheel-speed sensor: CF • Is resistance within 1.31.
ON-BOARD DIAGNOSTIC (ABS/TCS) DTC C1148, C1158, C1168, C1178, C1233, C1234, C1235, C1236 A6E697567650W11 Caution • When attaching the tester lead to the ABS (ABS/TCS) HU/CM harness connector, the SST (49 G066 001) must be used. (See P29 ABS (ABS/TCS) HU/CM INSPECTION.
ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION 1 VERIFY OTHER DTC HAS BEEN RECORDED • Have DTCs related to solenoid valve, pump motor, or pump motor relay been stored? P60 Yes No ACTION Go to applicable DTC inspection. Go to next step.
ON-BOARD DIAGNOSTIC (ABS/TCS) STEP INSPECTION 2 VERIFY IF CURRENT CONCERNED INPUT SIGNAL STATUS IS INTERMITTENT OR CONSTANT • Turn ignition key to OFF. • Connect WDS or equivalent to DLC-2. • Start engine and drive vehicle. • Access LF_WSPD, LR_WSPD, RF_WSPD and RR_WSPD using WDS or equivalent • Do vehicle speeds correspond approximately to the four PIDs above? 3 INSPECT WHEEL-SPEED SENSOR OUTPUT PULSE • Start engine and drive vehicle. • Inspect output voltage pattern using an oscilloscope.
ON-BOARD DIAGNOSTIC (ABS/TCS) STEP INSPECTION 8 INSPECT ABS (ABS/TCS) HU/CM OPERATION • Perform ABS (ABS/TCS) HU/CM system inspection. (See P27 ABS (ABS/TCS) HU/CM SYSTEM INSPECTION) • Is it okay? 9 VERIFY TROUBLESHOOTING COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory. See P46 Clearing DTCs Procedures • Start engine and drive vehicle at 10 km/h {6.2 mph} or above. • Gradually slow down vehicle and stop.
ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION 1 INSPECT ABS FUSE CONDITION • Is ABS fuse (60 A) okay? 2 3 4 5 INSPECT FAIL-SAFE RELAY POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect ABS (ABS/TCS) HU/CM connector. • Connect SST (adapter harness) to ABS (ABS/ TCS) HU/CM connector (harness side only). • Turn ignition key to ON (engine OFF). • Measure voltage between ABS (ABS/TCS) HU/CM terminal AA (harness side) of SST and ground.
ON-BOARD DIAGNOSTIC (ABS/TCS) DTC C1414 End Of Sie DTC C1414 DETECTION CONDITION POSSIBLE CAUSE A6E697567650W14 ABS (ABS/TCS) HU/CM mismatched installation • Detection of situation where vehicle-type or drive system input signal and ABS (ABS/TCS) HU/CM information remains incongruent through CAN information. • Mismatched installation of ABS (ABS/TCS) HU/CM Diagnostic procedure STEP INSPECTION 1 INSPECT ABS (ABS/TCS) UNIT FOR MISMATCHED INSTALLATION • Verify ABS (ABS/TCS) HU/CM part number.
ON-BOARD DIAGNOSTIC (ABS/TCS) Diagnostic procedure STEP INSPECTION 1 VERIFY OTHER DTC HAS BEEN RECORDED • Has any ABS wheel-speed sensor, sensor rotor, solenoid valve, pump motor, or motor relay related DTC been output? 2 INSPECT ABS (ABS/TCS) HU/CM OPERATION • Perform ABS (ABS/TCS) HU/CM system inspection. (See P27 ABS (ABS/TCS) HU/CM SYSTEM INSPECTION • Is it okay? 3 VERIFY CURRENT STATUS OF MALFUNCTION • Clear DTC from memory.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DSC SYSTEM WIRING DIAGRAM A6E697367650W01 A6E6920T005 .
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) 7 8 9 10 11 12 13 14 15 DSC OFF light DSC indicator light CAN driver Battery Cruise actuator DSC OFF switch DLC-2 CAN-H CAN-L 16 17 18 19 20 21 22 23 Wheel-speed sensor Combine sensor Steering angle sensor Brake switch Brake light Back-up light switch (MTX only) Back-up light Audio unit, Wiper and washer switch, Car-navegation unit, Auto leveling control unit DSC ON-BOARD DIAGNOSIS End Of Sie A6E697367650W02 On-Board Diagnostic (OBD) Test Description 1.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC WDS or equivalent C1234 Right front wheel-speed sensor/sensor rotor C1235 Right rear wheel-speed sensor/sensor rotor C1236 Left rear wheel-speed sensor/sensor rotor C1242 Left rear pressure reduction solenoid valve C1246 Right rear pressure reduction solenoid valve C1250 Left rear pressure retention solenoid valve C1254 Right rear ABS pressure retention solenoid valve C1266 C1280 Fail-safe relay Combine sensor C1400 Right front traction sw
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC WDS or equivalent U2516 Diagnosis system component Can communication Page (See T144 DTC U0073, U1900, U2516 ) PID/DATA Monitor Table PID Name (Definition) RPM (Engine speed signal input) Unit/Condition RPM Condition/Specification • Engine is stopped: 0 RPM • Engine is running: Indicates engine speed • Selector lever position is displayed ATX TRANSGR (Transaxle gear position) TRAC_SW (TCS OFF switch input) 1/2/3/4/P/R/N ON/OFF 1GR: 1 2GR: 2
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) PID Name (Definition) Unit/Condition BOO_ABS (Brake pedal switch input) ON/OFF ABS_LAMP (ABS warning light driver output state) ON/OFF BRAKE_LMP (BRAKE system warning light output state) ABSRR_O (Right rear ABS pressure reduction solenoid valve output state) ABSLR_O (Left rear ABS pressure reduction solenoid valve output state) ABSRF_O (Right front ABS pressure reduction solenoid valve output state) ABSLF_O (Left front ABS pressure reduction solenoid v
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) PID Name (Definition) Unit/Condition ABSVLVRLY (Fail-safe relay output state) ON/OFF ABSPMPRLY (Motor relay output state) ON/OFF SWA POS (Steering angle sensor input) DEG LF_WSPD (Left front wheel-speed sensor input) KPH or MPH RF_WSPD (Right front wheel-speed sensor input) KPH or MPH LR_WSPD (Left rear wheel-speed sensor input) RR_WSPD (Right rear wheel-speed sensor input) LAT ACC (Lateral-G sensor input) YAW_RATE (Yaw rate sensor input) MCYLI
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Active Command Modes Table Command Name RF_DSC_V LF_DSC_V ABS_POWER LR_OUTLET LR_INLET RR_INLET RR_OUTLET LF_INLET LF_OUTLET RF_INLET RF_OUTLET PMP_MOTOR RF_TC_VLV LF_TC_VLV TRAC OFF STAB_IND YAWRATE LATACCEL Definition Stability control solenoid valve (RF-LR) Stability control solenoid valve (LF-RR) Fail-safe relay Left rear ABS pressure reduction solenoid valve Left rear ABS pressure retention solenoid valve Right rear ABS pressure retention solenoid valve
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) P Diagnostic procedure STEP INSPECTION 1 INSPECT BATTERY VOLTAGE • Is battery terminal voltage okay? 2 INSPECT BATTERY GRAVITY • Is battery specific gravity as specified? 3 INSPECT CHARGING SYSTEM • Are generator and drive belt tension okay? 4 INSPECT DSC HU/CM POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Start engine. • Measure voltage between DSC HU/CM terminal G and ground.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC B1342 End Of Sie A6E697367650W04 Caution • When attaching the tester lead to the DSC HU/CM connector the SST (49 G066 004) must be used. DTC B1342 DETECTION CONDITION POSSIBLE CAUSE DSC HU/CM The on-board diagnostic function detects control module malfunction. • Malfunction of DSC HU/CM Diagnostic procedure STEP INSPECTION 1 VERIFY CURRENT STATUS OF MALFUNCTION • Clear DTC from memory.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) P Diagnostic procedure STEP INSPECTION 1 INSPECT DSC HU/CM TO BRAKE SWITCH FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect DSC HU/CM and brake switch connector • Inspect continuity DSC HU/CM terminal L and brake switch • Is there continuity? 2 INSPECT DSC HU/CM TO BRAKE SWITCH FOR SHORT TO GROUND • Turn ignition key to OFF. • Inspect continuity DSC HU/CM terminal L and ground • Is there continuity? 3 INSPECT BRAKE SWITCH • Inspect bake switch.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC B1627 A6E697367650W06 Caution • When attaching the tester lead to the DSC HU/CM connector the SST (49 G066 004) must be used. DTC B1627 DETECTION CONDITION POSSIBLE CAUSE P76 Reverse signal • Reverse signal is input for 10 seconds or more while driving at a vehicle speed of 65 km/h {40.3 mph}.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 CHECK TR SWITCH FOR DTCs (ATX) • Turn ignition key to OFF. • Connect WDS or equivalent to DLC-2. • Turn ignition key to ON (engine OFF). • Is DTC for TR switch obtained? 2 INSPECT BACK-UP LIGHT SWITCH (MTX) • Inspect back-up light switch. • Is it okay? 3 INSPECT REVERSE SIGNAL CIRCUIT FOR SHORT TO POWER (MTX) • Shift select lever to neutral position. • Turn ignition key to ON.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 VERIFY OTHER DTC HAS BEEN RECORDED • If any of DTC C1186 and/or C1266 has also been stored? 2 INSPECT ABS FUSE CONDITION • Is ABS fuse (60 A) okay? 3 4 P78 INSPECT MOTOR RELAY POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect DSC HU/CM connector. • Connect SST (adapter harness) to DSC HU/ CM connector (harness side only). • Turn ignition key to ON (engine OFF).
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION 5 VERIFY PUMP MOTOR OPERATION • Turn ignition key to OFF. • Remove SST (adapter harness) and connect all disconnected connectors. • Connect WDS or equivalent to DLC-2. • Turn ignition key to ON (engine OFF). • Access ABS_POWER and PMP_MOTOR active command modes using WDS or equivalent. • Does pump motor operate? 6 VERIFY TROUBLESHOOTING COMPLETED • Clear DTC from memory.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 CHECK FOR PCM FOR DTCs • Turn ignition key to OFF. • Connect WDS or equivalent to DLC-2 • Turn ignition key to ON (engine OFF). • Is DTC for engine control system obtained? 2 MONITOR CAN SIGNAL • Access PID RPM and TP using WDS or equivalentI. • Are engine speed and throttle position within specification? 3 VERIFY TROUBLESHOOTING COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1140 DTC C1140 DETECTION CONDITION POSSIBLE CAUSE A6E697367650W11 DSC HU/CM (pump) Right front and left rear wheels, or left front and right rear wheel-lock is detected during DSC operation. Stuck pump motor in DSC HU/CM Diagnostic procedure STEP INSPECTION 1 INSPECT DSC HU/CM OPERATION • Perform DSC HU/CM system inspection. (See P35 DSC SYSTEM INSPECTION) • Is it okay? 2 INSPECT CONVENTIONAL BRAKE OPERATION • Inspect brake fluid level.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 INSPECT WHEEL-SPEED SENSOR CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect DSC HU/CM connector. • Measure resistance between suspected sensor terminals of DSC HU/CM connector (harness side). RF wheel-speed sensor: MI LF wheel-speed sensor: FJ RR wheel-speed sensor: KH LR wheel-speed sensor: QN • Is resistance within 1.31.7 kilohm? P82 ACTION Yes No Go to next step. Go to Step 3.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION 2 INSPECT WHEEL-SPEED SENSOR CIRCUIT FOR SHORT TO GROUND • Turn ignition key to OFF. • Inspect continuity between suspected sensor terminal(s) of DSC HU/CM connector (harness side) and ground(s).
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 VERIFY OTHER DTC HAS BEEN RECORDED • Have DTCs related to solenoid valve, pump motor, or pump motor relay been stored? P84 Yes No ACTION Go to applicable DTC inspection. Go to next step.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION 2 VERIFY IF CURRENT CONCERNED INPUT SIGNAL STATUS IS INTERMITTENT OR CONSTANT • Turn ignition key to OFF. • Connect WDS or equivalent to DLC-2. • Start engine and drive vehicle. • Access LF_WSPD, LR_WSPD, RF_WSPD and RR_WSPD using WDS or equivalent. • Do vehicle speeds correspond approximately to the four PIDs above? 3 INSPECT WHEEL-SPEED SENSOR OUTPUT PULSE • Start engine and drive vehicle.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION 8 INSPECT DSC HU/CM OPERATION • Perform DSC HU/CM system inspection. • See P35 DSC SYSTEM INSPECTION • Is it okay? 9 VERIFY TROUBLESHOOTING COMPLETED • Make sure to reconnect all disconnected connectors. • Clear DTC from memory. (See P46 Clearing DTCs Procedures) • Start engine and drive vehicle at 10 km/h {6.2 mph} or above. • Gradually slow down vehicle and stop.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 INSPECT ABS FUSE CONDITION • Is ABS fuse (60 A) okay? 2 4 5 6 INSPECT FAIL-SAFE RELAY POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect DSC HU/CM connector. • Connect SST (adapter harness) to DSC HU/ CM connector (harness side only). • Turn ignition key to ON (engine OFF). • Measure voltage between DSC HU/CM terminal C (harness side) of SST and ground.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION 2 VERIFY TROUBLESHOOTING COMPLETED • Clear DTC from memory. (See P46 Clearing DTCs Procedures) • Start engine and drive vehicle at 10 km/h {6.2 mph} or above. • Gradually slow down and stop vehicle. • Is same DTC present? 3 VERIFY AFTER REPAIR PROCEDURE • Is there any other DTC present? DTC C1280, C1730, C1951, C1952, C1959 Yes No ACTION Replace DSC HU/CM, then go to next step. Go to next step. Yes No Go to applicable DTC inspection.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1280, C1730, C1951, C1952, C1959 Combine sensor • C1280: Yaw rate sensor part 0-point correction value is 3 or more, or 2 or less. Output voltage value from yaw rate sensor part remains absolutely unchanged. Difference between estimated yaw rate value, calculated from wheel speed-sensor, lateral-G sensor, steering angle sensor, and the value output from yaw rate sensor exceeds specification.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 INSPECT COMBINE SENSOR POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to ON (engine OFF). • Measure voltage between combine sensor terminal C (harness side) of and ground. • Is voltage 4.55.5 V? 2 INSPECT COMBINE SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect DSC HU/CM and yaw rate sensor connectors.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1414 End Of Sie DTC C1414 DETECTION CONDITION POSSIBLE CAUSE A6E697367650W16 DSC HU/CM mismatched installation • Detection of situation where vehicle-type or drive system input signal and DSC HU/CM information remains incongruent through CAN information • Mismatched installation of DSC HU/CM Diagnostic procedure STEP INSPECTION 1 INSPECT DSC HU/CM FOR MISMATCHED INSTALLATION • Verify DSC HU/CM part number • Has a DSC HU/CM with the correct part number
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1510, C1511, C1512, C1513 C1510 C1511 DTC C1512 C1513 DETECTION CONDITION POSSIBLE CAUSE • • • • • • A6E697367650W21 RF solenoid valve, motor or RF wheel-speed sensor/sensor rotor LF solenoid valve, motor or LF wheel-speed sensor/sensor rotor RR solenoid valve, motor or RR wheel-speed sensor/sensor rotor LR solenoid valve, motor or LR wheel-speed sensor/sensor rotor Wheel lock is detected during ABS operation (pressure reduction inoperative).
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC C1955, C1956 A6E697367650W19 Caution • When attaching the tester lead to the DSC HU/CM connector the SST (49 G066 004) must be used. DTC C1955, C1956 Steering angle sensor • C1955: Output voltages from steering angle sensors 1 and 2 are not at 1 V or less, or not at 3.25 V or more. DETECTION • C1956: CONDITION Sensor 1 voltage remains unchanged, sensor 2 voltage changes. Sensor 2 voltage remains unchanged, sensor 1 voltage changes.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 INSPECT STEERING ANGLE SENSOR POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to ON (engine OFF). • Measure voltage between steering angle sensor terminal A (harness side) and ground. • Is voltage B+? 2 INSPECT STEERING ANGLE SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT • Turn ignition key to OFF. • Disconnect DSC HU/CM and steering angle sensor connectors.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) STEP INSPECTION 3 INSPECT STEERING ANGLE SENSOR SIGNAL CIRCUIT FOR OPEN CIRCUIT • Inspect continuity between DSC HU/CM terminal (harness side) and steering angle sensor terminal (harness side) below.
ON-BOARD DIAGNOSTIC (DYNAMIC STABILITY CONTROL) DTC U2021 A6E697367650W22 Note • To warm up the engine completely, idle the engine and wait for more than 5 minutes. DTC U2021 DETECTION CONDITION POSSIBLE CAUSE Engine coolant temperature • After engine is warmed up, engine coolant temperature is 0 °C {32 °F} or less, and TCS operation is inhibited by PCM. • System is normal. When engine coolant temperature rises, TCS operation is executed by PCM.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) SYSTEM WIRING DIAGRAM A6E699067650W01 ABS (ABS/TCS) P A6E6921T001 .
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) DSC A6E6920T005 .
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) 13 14 15 16 17 18 DLC-2 CAN-H CAN-L Wheel-speed sensor Combine sensor Steering angle sensor 19 20 21 22 23 Brake switch Brake light Back-up light switch (MTX only) Back-up light Audio unit, Wiper and washer switch, Car-navegation unit, Auto leveling control unit FOREWORD End Of Sie A6E699067650W02 • Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic Inspection. To check the DTC, follow the DTC Inspection steps.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Warning lights that may illuminate and/or flash All the following lights illuminate: • TCS OFF light Cases in which the light may illuminate When the engine coolant temperature is below 0°°C {32 F}.(*2) Conditions in which the light will go out When engine is started and engine coolant temperature rises above 0°°C {32 F}.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Vehicle with DSC 1. The ABS warning light and/or BRAKE system warning light and/or DSC indicator light and/or TSC OFF light illuminate even when the system is normal.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) (2) Malfunction in hydraulic system • Symptom in hydraulic system malfunction are similar to those in a conventional brake malfunction. However, it is necessary to determine if the malfunction is in a DSC component or the conventional brake system. • The hydraulic unit contains delicate mechanical parts. If foreign materials get into the component, the DSC may fail to operate.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) 4. Shake each connector or wire harness a bit vertically and horizontally while monitoring the PID. • If PID value is unstable, check for poor connection. YDE6980W002 Inspection method for sensors 1. Connect WDS or equivalent to DLC-2. 2. Turn ignition key to ON (Engine OFF). Note • If engine starts and runs, perform the following steps at idle. 3. Access PIDs for the switch you are inspecting. 4. Vibrate the sensor slightly with your finger.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) SYMPTOM TROUBLESHOOTING • Verify the symptoms, and perform troubleshooting according to the appropriate number. Vehicles with ABS/TCS No. 1 2 3 4 5 6 7 8 9 10 11 A6E699067650W04 Symptom ABS warning light, BRAKE system warning light, TCS OFF light do not illuminate with ignition switch on. Neither ABS warning light nor BRAKE system warning light illuminate with ignition switch on. ABS warning light does not illuminate with ignition switch on.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Vehicle with ABS/TCS P A6E6980W002 P105
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Vehicle with DSC A6E6980W001 End Of Sie P106
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.1 ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, TCS OFF LIGHT DO NOT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W05 Vehicle with ABS/TCS ABS warning light, BRAKE system warning light, TCS OFF light do not illuminate with ignition switch on.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.2 NEITHER ABS WARNING LIGHT NOR BRAKE SYSTEM WARNING LIGHT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W06 2 Neither ABS warning light nor BRAKE system warning light illuminate with ignition switch on.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.3 ABS WARNING LIGHT DOES NOT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W07 3 ABS warning light does not illuminate with ignition switch on. [TROUBLESHOOTING HINTS] • Malfunction of instrument cluster or ABS/TCS HU/CM Diagnostic procedure STEP INSPECTION 1 COMFIRM DTC U1900 USING WDS OR EQUIVALENT • Retrieve DTC from PCM, ABS/TCS and instrument cluster.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.5 TCS OFF LIGHT, TCS INDICATOR LIGHT DO NOT ILLUMINATE WITH IGNITION SWITCH ON A6E699067650W09 5 TCS OFF light , TCS indicator light do not illuminate with ignition switch on.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION P • When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunction. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged. NO.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION 4 INSPECT PID/DATA IN ABS/TCS HU/CM Inspect the following items using WDS or equivalent PID/DATA monitor function. • ABS_LAMP (ABS warning light) • BRAKE_ LAMP (BRAKE system warning light) • ABS_VOLT (power supply voltage) Is ABS_LAMP and BRAKE_LAMP ON after more than 4 seconds with ignition switch on? 5 INSPECT ABS/TCS HU/CM IGNITION POWER SUPPLY SYSTEM (TERMINAL Z) Check the voltage for PID/DATA monitor ABS_VOLT item.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP INSPECTION ACTION P NO.7 ABS WARNING LIGHT STAYS ON MORE THAN 4 SECONDS WITH IGNITION SWITCH ON End Of Sie A6E699067650W11 7 ABS warning light stays on more than 4 seconds with ignition switch on. [TROUBLESHOOTING HINTS] • ABS/TCS CM detects ABS system malfunction. Diagnostic procedure STEP INSPECTION 1 INSPECT WIRING HARNESS BETWEEN ABS/ TCS HU/CM AND DLC-2 (DATA LINK CONNECTOR-2) FOR CONTINUITY AND SHORTS Perform DTC inspection.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) STEP *6 INSPECTION INSPECT WIRING HARNESS BETWEEN ABS/ TCS HU/CM AND DLC-2 (DATA LINK CONNECTOR-2) FOR SHORT TO GROUND Is there continuity between SST connector terminal X and ground? Yes No ACTION Repair wiring harness between ABS/TCS HU/CM and data link connector. Replace ABS/TCS HU/CM (communication circuit malfunction is ABS/TCS HU/CM).
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) 4 5 *6 *7 *8 INSPECT PID/DATA IN ABS/TCS HU/CM Inspect (BRAKE system warning light) using WDS or equivalent PID/DATA monitor function. Is BRAKE_LAMP on after more than 4 seconds with ignition switch on? VERIFY WHETHER MALFUNCTION IS IN PARKING BRAKE SWITCH OR BRAKE FLUID LEVEL SENSOR, OR IN SOME OTHER PART Disconnect the following in order: 1. Parking brake switch connector 2.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.9 TCS OFF LIGHT STAYS ON MORE THAN 4 SECONDS WITH IGNITION SWITCH ON A6E699067650W13 BRAKE system warning light stays on more than 4 seconds with ignition switch on. (Parking brake 9 is released.) [TROUBLESHOOTING HINTS] • Warning light circuit open or shorted to ground in ABS/TCS HU/CM 1 2 3 *4 *5 *6 *7 *8 INSPECT WIRING HARNESS BETWEEN ABS/ TCS HU/CM AND DLC-2 (DATA LINK CONNECTOR-2) FOR CONTINUITY AND SHORTS Perform DTC inspection.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.10 TCS DOES NOT WORK CORRECTLY A6E699067650W14 10 TCS does not work correctly. [TROUBLESHOOTING HINTS] • There is difference in size or air pressure between the front and rear tires. • There is malfunction in the engine control system. • ABS/TCS HU/CM detects TCS system malfunction. Diagnostic procedure STEP INSPECTION 1 CHECK TIRE SIZE AND AIR PRESSURE Inspect tire size and air pressure.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) Diagnostic procedure STEP INSPECTION 1 CHECK FOR DTCS IN DSC HU/CM • Check the DTC for the DSC ON-BOARD DIAGNOSTIC SYSTEM.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.2 ANY OF THE FOLLOWING LIGHTS STAY ON: (ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR DSC OFF LIGHT) A6E699067650W17 Any of the following lights stay on: (ABS warning light, BRAKE system warning light, DSC indicator 2 light and/or DSC OFF light) [TROUBLESHOOTING HINTS] • Brake fluid amount is low. • Parking brake does not release.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.3 THERE IS A MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND DSC OFF LIGHT DO NOT ILLUMINATE A6E699067650W18 There is a malfunction in the system even though ABS warning light, BRAKE system warning light, 3 DSC indicator light and DSC OFF light do not illuminate. [TROUBLESHOOTING HINTS] • There is mechanical malfunction in system.
TROUBLESHOOTING (ABS/TCS/DYNAMIC STABILITY CONTROL) NO.5 DSC*2 OPERATES FREQUENTLY/DSC DOES NOT WORK CORRECTLY*2: DSC INDICATOR LIGHT GOES ON AND OFF WHILE DSC OPERATES A6E699067650W20 DSC (*2) operates frequently. /DSC does not work correctly. 5 (*2): DSC indicator light goes on and off while DSC operates.
SUSPENSION R LOCATION INDEX .................................................R-2 FRONT SUSPENSION LOCATION INDEX.........R-2 REAR SUSPENSION LOCATION INDEX ...........R-3 GENERAL PROCEDURES ....................................R-4 PRECAUTION (SUSPENSION) ..........................R-4 WHEEL ALIGNMENT.............................................R-4 WHEEL ALIGNMENT PRE-INSPECTION...........R-4 FRONT WHEEL ALIGNMENT.............................R-5 REAR WHEEL ALIGNMENT ...............................
LOCATION INDEX LOCATION INDEX FRONT SUSPENSION LOCATION INDEX A6E740001015W01 A6E7414W033 .
LOCATION INDEX REAR SUSPENSION LOCATION INDEX A6E740001016W01 R A6E7416W016 .
GENERAL PROCEDURES , WHEEL ALIGNMENT GENERAL PROCEDURES PRECAUTION (SUSPENSION) Wheels and Tires Removal/Installation 1. When a wheel is installed, tighten it to 88118 N·m {9.012.0 kgf·m, 65.087.0 ft·lbf}. A6E741001013W01 Suspension Links Removal/Installation 1. Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded. Note • Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified levels.
WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT A6E741201015W01 Specification (Unloaded)*1 Normal Item Total toe-in Maximum steering angle Empty (mm {in}) (degree) Inner Outer Caster angle*2 (reference value) Fuel gauge indication 1/4 1/2 3/4 Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.
WHEEL ALIGNMENT REAR WHEEL ALIGNMENT A6E741201016W01 Specification (Unloaded)*1 Normal Item Empty (mm {in}) (degree) Total toe-in Camber angle*2 Thrust angle 1°05′±1° Fuel gauge indication 1/4 1/2 3/4 Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12} 0°11′±0°22′ 1°07′±1° (degree) 1°09′±1° 1°11′±1° Full 1°13′±1° 0°±0°48′ Elevated*3 Item Empty (mm {in}) (degree) Total toe-in Camber angle*2 Thrust angle 0°56′±1° (degree) Fuel gauge indication 1/4 1/2 3/4 Tire: 2±4 {0.08±0.
WHEEL ALIGNMENT, WHEEL AND TIRE 2. Adjust the toe-in turning the adjusting link. Specification Total Toe-in: 2± ±4 mm {0.08± ±0.16 in} Note • Toe change amount: 0°43′ / one rotation A6E7412W005 3. Tighten the locknut. Tightening torque 68.698.1 N·m {7.010.0 kgf·m, 50.672.3 ft·lbf} A6E7412W004 End Of Sie R WHEEL AND TIRE WHEEL BALANCE ADJUSTMENT (16 INCH AND 17 INCH ALUMINUM ALLOY WHEEL) A6E741701014W01 Caution • Adjust the outer wheel balance first, then the inner wheel balance.
WHEEL AND TIRE 6. If attaching 2 balance weights, position them so that each is on either side of the position indicated by the wheel balancer. Caution • Do not attach weight balances in a row. • Do not overlap the balance weights. • Total weight must not exceed 160g {5.65 oz}. Z5U0212W102 Knock-type Balance Weight (Inner) 1. Measure the amount of unbalance with a wheel balancer. 2. Attach a balance weight corresponding to the measured weight value on the position (inner) indicated by the wheel balancer.
FRONT SUSPENSION FRONT SUSPENSION FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION A6E741404910W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle. 1.
FRONT SUSPENSION Bolt (Front Shock Absorber Lower Side) Removal Note 1. Support the knuckle with a jack to prevent from falling. Piston Rod Nut Removal Note Warning • Removing the piston rod nut is dangerous. The shock absorber and spring could fly off under tremendous pressure and cause serious injury or death. Secure the shock absorber in the SSTs before removing the piston rod nut. 1. Protect the coil spring using a piece of cloth, then set the SSTs. 2.
FRONT SUSPENSION 4. Compress the coil spring using the SSTs. 5. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat. 6. Make sure that the marks on the shock absorber and dust boot are aligned. 7. Install the mounting rubber and piston rod nut, then remove the SSTs. Piston rod nut tightening torque 39.252.9 N·m {4.005.39 kgf·m, 29.039.0 ft·lbf} A6E7414W029 Front Shock Absorber and Coil Spring Installation Note 1.
FRONT SUSPENSION Damper Fork Installation Note 1. Align the gap of the damper fork with the projections of the damper. 2. Tighten the bolt. A6E7414W005 End Of Sie FRONT SHOCK ABSORBER INSPECTION 1. 2. 3. 4. A6E741434700W01 Remove the front shock absorber from the vehicle. Inspect for damage and oil leakage. Inspect the rubber bushing for deterioration and wear. Compress and extend the shock piston at least three times.
FRONT SUSPENSION FRONT UPPER ARM REMOVAL/INSTALLATION A6E741434200W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle. 1. Remove in the order indicated in the table. 2.
FRONT SUSPENSION 2. Separate the ball joint from the knuckle using the SST. A6E7414W006 Bolt (Front Upper Arm) Removal Note 1. Remove the nuts (3 locations) from the upper part of the front shock absorber. 2. Pull the front shock absorber and coil spring out of the way, towards the outer side of the vehicle. 3. Remove the bolts. A6E7414W023 Clip Installation Note 1. Wipe the grease off the ball stud. 2. Fill the inside of the new dust boot with grease. 3. Install the boot on the ball joint. 4.
FRONT SUSPENSION FRONT LOWER ARM (FRONT) REMOVAL/INSTALLATION End Of Sie A6E741434300W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. R A6E7414W018 .
FRONT SUSPENSION Front Lower Arm (Front) Ball Joint Removal Note 1. Separate the ball joint from the knuckle using the SSTs. A6E7414W030 Front Lower Arm (Front) Bushing (Inner Side) Removal Note 1. Press the bushing (inner side) out using the SSTs. A6E7414W001 Front Lower Arm (Front) Bushing (Outer Side) Removal Note 1. Press the bushing (outer side) out using the SSTs. A6E7414W010 Front Lower Arm (Front) Bushing (Outer Side) Installation Note 1. Mark the new bushing as shown in the figure.
FRONT SUSPENSION 2. Press the bushing in to the marking using the SSTs. A6E7414W012 3. Verify that clearance distance AB is 8.75 mm 10.75 mm {0.3445 in0.4232 in}. A6E7414W003 Front Lower Arm (Front) Bushing (Inner Side) Installation Note 1. Mark the new bushing as shown in the figure. R A6E7414W013 2. Press the bushing in to the marking using the SSTs.
FRONT SUSPENSION 3. Verify that clearance distance AB is 12.75 mm14.75 mm {0.5020 in0.5807 in}. A6E7414W007 Clip Installation Note 1. Wipe the grease off the ball stud. 2. Fill the inside of the new dust boot with grease. 3. Install the boot on the ball joint. 4. Install the new clip using the SST. 5. Verify that the clip is installed securely to the groove. 6. Wipe away the excess grease. A6E7414W025 End Of Sie FRONT LOWER ARM (FRONT) INSPECTION 1. Remove the lower arm (front) from the vehicle. 2.
FRONT SUSPENSION FRONT LOWER ARM (REAR) REMOVAL/INSTALLATION 1. Remove the front crossmember component. (See R23 FRONT CROSSMEMBER REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Inspect the front wheel alignment. (See R5 FRONT WHEEL ALIGNMENT.) A6E741434300W02 R A6E7414W019 .
FRONT SUSPENSION Front Lower Arm (Rear) Bushing Removal Note 1. Press the bushing out using the SSTs. 2. Remove the front lower arm (rear) from the press and tap the bushing out with a hammer. A6E7414W014 Front Lower Arm (Rear) Bushing Installation Note 1. Mark the new bushing as shown in the figure. A6E7414W026 2. Press the bushing in to the marking using the SSTs. A6E7414W027 3. Verify that clearance distance AB is 23.75 mm25.75 mm {0.936 in1.013 in}.
FRONT SUSPENSION Clip Installation Note 1. Wipe the grease off the ball stud. 2. Fill the inside of the new dust boot with grease. 3. Install the boot on the ball joint. 4. Install the new clip using the SST. 5. Verify that the clip is installed securely to the groove. 6. Wipe away the excess grease. A6E7414W025 Front Lower Arm (Rear) Installation Note 1. Install the lower arm (rear) so that identification mark (L or R) faces toward the front of the vehicle.
FRONT SUSPENSION FRONT STABILIZER REMOVAL/INSTALLATION 1. Remove the front crossmember component. (See R23 FRONT CROSSMEMBER REMOVAL/ INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the headlight zeroset. (See T31 HEADLIGHT ZEROSET.) 5. Inspect the front wheel alignment. (See R5 FRONT WHEEL ALIGNMENT.) .
FRONT SUSPENSION STABILIZER CONTROL LINK INSPECTION 1. Remove the stabilizer control link from the vehicle. 2. Inspect for bending and damage. 3. Measure the ball joint starting torque. (1) Rock the ball joint stud side to side 10 times. (2) Rotate the ball joint stud 10 times. (3) Measure the starting torque using a suitable allen socket and a torque wrench. A6E741434150W01 Starting torque 0.230.47 N·m {2.44.7 kgf·cm, 2.14.
FRONT SUSPENSION A6E7414W100 . 1 2 3 4 5 6 Nut (stabilizer control link) Front lower arm (front) ball joint (See R16 Front Lower Arm (Front) Ball Joint Removal Note) Front lower arm (rear) ball joint (See R19 Front Lower Arm (Rear) Ball Joint Removal Note) Bolt (front shock absorber lower side) No.1 engine mount center bolt (See R25 No.
FRONT SUSPENSION No.1 Engine Mount Center Bolt Removal Note 1. Suspend the engine using the SST. 2. Remove the No.1 engine mount center bolt. A6E7414W016 Crossmember Bracket Removal Note Warning • Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death. Verify that the jack securely supports the crossmember component before removing the crossmember bracket. 1. Support the crossmember component with a jack and remove the nuts. 2.
FRONT SUSPENSION Front Crossmember Bushing Installation Note 1. Set the bushings as shown in the figure. A6E7414W041 2. Install the bushing onto the crossmember using the SSTs.
FRONT SUSPENSION TRANSVERSE MEMBER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 1 2 3 A6E741434890W01 Transverse member and transverse cover Transverse cover (European (L.H.D. U.K.) specs.) (See R27 Transverse Cover Installation Note) Transverse member 2. Install in the reverse order of removal. A6E7414W037 Transverse Cover Installation Note 1. Install the transverse cover. 2. Stake area A as shown in the figure.
REAR SUSPENSION REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL/INSTALLATION A6E741628700W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle. 1.
REAR SUSPENSION REAR COIL SPRING REMOVAL/INSTALLATION 1. Remove the rear auto leveling sensor. (See T32 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the headlight zeroset. (See T31 HEADLIGHT ZEROSET.) 5. Inspect the rear wheel alignment. (See R6 REAR WHEEL ALIGNMENT.) A6E741628011W01 R A6E7416W022 .
REAR SUSPENSION Bound Stopper (Body Side) Removal/Installation Note 1. Remove or/and install the bound stopper (body side) using the extension bar. Rear Coil Spring Installation Note 1. Install the coil spring so that the distinguisher mark is located on under side. 2. Position the jack under the lower arm and jack up slowly. Warning • Installing the coil spring is dangerous. The coil spring could fly off, and cause serious injure of death. 3. Install the lower arm (outer side) bolt.
REAR SUSPENSION REAR UPPER ARM REMOVAL/INSTALLATION A6E741628210W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle. 1. Remove in the order indicated in the table. 2.
REAR SUSPENSION Bolt (Rear Shock Absorber Lower Side) Removal Note 1. Support the trailing link with a jack. A6E7416W005 Bolt (Rear Upper Arm) Removal Note 1. Loosen the bolts on the inner and outer side of the lateral link. Rear Upper Arm Bushing Removal Note 1. Press the upper arm bushing out using the SSTs. A6E7416W010 Rear Upper Arm Bushing Installation Note 1. Mark the new bushing as shown in the figure. A6E7416W011 2. Press the bushing in to the marking using the SSTs.
REAR SUSPENSION 3. Verify that clearance distance AB is 14.0 mm 16.0 mm {0.56 in-0.62 in}. A6E7416W013 End Of Sie REAR LATERAL LINK REMOVAL/INSTALLATION A6E741628600W01 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake.
REAR SUSPENSION Bolt (Rear Shock Absorber Lower Side) Removal Note 1. Support the trailing link with a jack. Caution • Removing the trailing link is dangerous. The trailing link could fall and cause serious injury or death. Verify that the jack securely supports the trailing link. A6E7416W005 End Of Sie REAR STABILIZER REMOVAL/INSTALLATION 1. Remove the rear auto leveling sensor. (See T32 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3.
REAR SUSPENSION STABILIZER CONTROL LINK INSPECTION 1. Remove the stabilizer control link from the vehicle. 2. Inspect for bending and damage. 3. Measure the ball joint starting torque. (1) Rock the ball joint stud side to side 10 times. (2) Rotate the ball joint stud 10 times. (3) Measure the starting torque using a suitable Allen socket and a torque wrench. A6E741634150W01 Starting torque 0.230.47 N·m {2.44.7 kgf·cm, 2.14.
REAR SUSPENSION A6E7416W018 .
REAR SUSPENSION Caliper Component Removal Note 1. Suspend the caliper aside with cable. Bolt (Trailing Link Front Side) Removal Note 1. Support the trailing link with a jack. Caution • Removing the trailing link is dangerous. The trailing link could fall and cause serious injury or death. Verify that the jack securely supports the trailing link. 2. Remove the bolts (trailing link front side). A6E7416W005 Bolt (Rear Lateral Link Outer Side) Removal Note 1. Loosen the bolt (lateral link inner side). 2.
REAR SUSPENSION A6E7416W020 .
REAR SUSPENSION 8 9 10 11 12 Rear lower arm (See R30 REAR LOWER ARM REMOVAL/ INSTALLATION) Bolt (rear shock absorber lower side) Bolt (trailing link front side) (See R39 Bolt (Trailing Link Front Side) Removal Note) (See R40 Bolt (Trailing Link Front Side) Installation Note) Nut (crossmember) Crossmember component (See R39 Crossmember Component Removal Note) 13 14 15 16 17 18 Trailing link Rear lateral link Rear upper arm Rear stabilizer Rear crossmember Rear crossmember Bushing (See R39 Rear Cross
REAR SUSPENSION Rear Crossmember Bushing Installation Note 1. Set the bushings as shown in the figure. 2. Tap the bushing onto the rear crossmember using the SSTs. A6E7416W021 A6E7416W002 Bolt (Trailing Link Front Side) Installation Note 1. Support the trailing link with a jack. 2. Tighten the bolts (trailing link front side).
BODY S LOCATION INDEX ................................................. S-4 EXTERIOR........................................................... S-4 INTERIOR............................................................ S-6 DOOR .................................................................. S-9 BONNET ............................................................... S-10 BONNET REMOVAL/INSTALLATION ............... S-10 BONNET ADJUSTMENT................................... S-10 FRONT FENDER PANEL............
MOLDING ............................................................. S-55 FRONT BELTLINE MOLDING REMOVAL ........ S-55 FRONT BELTLINE MOLDING INSTALLATION............................................... S-55 REAR BELTLINE MOLDING REMOVAL...........S-56 REAR BELTLINE MOLDING INSTALLATION............................................... S-56 ROOF MOLDING REMOVAL ............................ S-57 ROOF MOLDING INSTALLATION .................... S-57 OUTSIDE MIRROR...............................................
SEAT................................................................... S-105 FRONT SEAT REMOVAL/INSTALLATION ..... S-105 FRONT SEAT DISASSEMBLY/ASSEMBLY ... S-106 REAR SEAT REMOVAL/INSTALLATION ....... S-110 REAR SEAT DISASSEMBLY/ASSEMBLY ...... S-112 REMOTE HANDLE LEVER REMOVAL/INSTALLATION.......................... S-114 SEAT BACK STRIKER REMOVAL/INSTALLATION.......................... S-115 POWER SEAT SWITCH INSPECTION........... S-115 FRONT TILT MOTOR INSPECTION ...............
LOCATION INDEX LOCATION INDEX EXTERIOR A6E770001086W01 Front A6E7700W001 .
LOCATION INDEX Rear A6E7700W002 .
LOCATION INDEX INTERIOR A6E770001086W02 Front A6E7700W003 .
LOCATION INDEX 21 22 Recliner motor (See S116 RECLINER MOTOR INSPECTION) Power seat switch (See S115 POWER SEAT SWITCH INSPECTION) 23 Seat warmer unit (See S118 SEAT WARMER UNIT INSPECTION) Rear S A6E7700W004 .
LOCATION INDEX 11 12 13 14 15 16 17 Rear door trim (See S90 REAR DOOR TRIM REMOVAL/ INSTALLATION) C-pillar trim (See S89 C-PILLAR TRIM REMOVAL/ INSTALLATION) Rear buckle (See S102 REAR BUCKLE REMOVAL/ INSTALLATION) Trunk side trim (See S92 TRUNK SIDE TRIM REMOVAL/ INSTALLATION) Trunk side upper trim (See S93 TRUNK SIDE UPPER TRIM REMOVAL/INSTALLATION) Trunk end trim (See S93 TRUNK END TRIM REMOVAL/ INSTALLATION) Rear center seat belt (See S101 REAR CENTER SEAT BELT REMOVAL/INSTALLATION ) (See S10
LOCATION INDEX DOOR A6E770001086W03 A6E7700WH01 .
BONNET BONNET BONNET REMOVAL/INSTALLATION A6E771001084W01 Warning • Removing the bonnet without supporting can be dangerous. The bonnet may fall and injure you. Always perform the following procedure with at least another person. 1. 2. 3. 4. 5. Disconnect the windshield washer hose. To remove the bonnet hinge, remove the front fender panel. To remove the bonnet lock, remove the radiator grille. To remove the bonnet release cable, remove the driver-side mud guard.
BONNET 4. Verify that the gap between the bonnet and the body is within the specification. Clearance a: 2.54.5 mm {0.080.17 in} A6E7710W004 Height Adjustment 1. Turn the stop rubber to adjust the height of the bonnet. A6E7710W006 S A6E7710W003 2. Verify that the height between the bonnet and the body is within the specification. Clearance a: 3.06.0 mm {0.120.23 in} b: 3.06.0 mm {0.120.23 in} c: -1.01.0 mm {-0.040.
FRONT FENDER PANEL FRONT FENDER PANEL FRONT FENDER PANEL REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 1 2 A6E771252110W01 Disconnect the negative battery cable. Remove the front side turn light. Remove the fender molding. (See S50 COWL GRILLE REMOVAL/INSTALLATION.) Remove the front bumper. (See S47 FRONT BUMPER REMOVAL/INSTALLATION.) Remove the front combination light. (See T26 FRONT COMBINATION LIGHT REMOVAL/INSTALLATION.) Remove in the order indicated in the table. Front fender panel Seal plate 7.
DOOR DOOR FRONT DOOR STRUCTURAL VIEW A6E771458010W01 S A6E7714W001 .
DOOR REAR DOOR STRUCTURAL VIEW A6E771472010W01 A6E7714W002 .
DOOR FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. To remove the front door hinge, remove the front fender panel. 3. To remove the checker, remove the door speaker. 4. Remove in the order indicated in the table. 1 2 3 4 A6E771458010W02 Connector (See S15 Connector Removal Note) Front door hinge Front door Checker 5. Install in the reverse order of removal. 6. Adjust the front door. (See S16 DOOR ADJUSTMENT.) A6E7714W006 Connector Removal Note 1.
DOOR End OfADJUSTMENT Sie DOOR A6E771458010W03 1. Measure the gap and height between the front or rear door and the body. 2. If not as specified, loosen the front or rear door hinge installation bolts or the door lock striker installation screws, and reposition the door. Clearance a: 2.54.5 mm {0.100.18 in} b: -0.81.2 mm {-0.030.05 in} c: -0.31.7 mm {-0.010.07 in} d: -1.01.0 mm {-0.040.04 in} e: -0.51.5 mm {-0.020.06 in} A6E7714W025 3. Tighten the bolts or screws.
DOOR 5. Remove the screws. 6. Insert your hand in hole of the front door unit, and lift out the front door glass. 7. Install in the reverse order of removal. A6E7714W003 End OfDOOR Sie GLASS REMOVAL/INSTALLATION REAR 1. 2. 3. 4. 5. 6. Fully down the rear door glass. Remove the rear door trim. Remove the hole cover. Pull up the rear door weatherstrip and remove the screw. Remove the bolt. Remove the glass run channel from the rear door glass guide. A6E771472510W01 S A6E7714W014 7.
DOOR FRONT DOOR UNIT REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. A6E771458971W01 Remove the front door glass. Remove the inner handle. Remove the front door speaker. Disconnect the power window motor connector, front door lock actuator connector, power outside mirror connector. Remove the door harness from the front door unit. Remove the bolts. Remove the screw. Remove the front door actuator hook from the front door unit.
DOOR 10. For power window system-equipped vehicles, remove the power window motor and power window regulator from the door unit. For manual window system-equipped vehicles, remove the regulator handle and manual window regulator. 11. Install in the reverse order of removal. A6E7714W017 End Of Sie FRONT DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION 1. Remove the front door unit. 2. Remove the screws, then remove the front door latch and door lock actuator. 3. Install in the reverse order of removal.
DOOR FRONT DOOR KEY CYLINDER REMOVAL/INSTALLATION 1. Remove the front door unit. 2. Remove the cover, then remove the bolt. A6E771458310W03 A6E7714W027 3. For protector-equipped vehicles, pull out the protector tab from the latch and remove the protector. 4. Disconnect the rod. 5. Remove the front outer handle. A6E7714W028 6. Turn the key cylinder in the direction indicated by the arrow (1) and move the hook to the notch. 7. Pull the key cylinder towards you (2) to remove it. 8.
DOOR FRONT OUTER HANDLE REMOVAL/INSTALLATION 1. 2. 3. 4. Remove the front door glass. Detach the outer handle and front door latch rod. For protector-equipped vehicles, refer to key cylinder removal/installation to remove the protector. Remove the bolts. A6E771458410W01 A6E7714W004 5. With the rear side of the outer handle fixed and the outer handle lever pulled out (1), remove the rear side of the outer handle from the front door. 6. Pull out the front side of the outer handle from the front door. 7.
DOOR INNER HANDLE REMOVAL/INSTALLATION 1. Remove the front door trim. 2. Using a flathead screwdriver, press and hold the hook in the direction indicated by arrow (1), and pull the shaft in the direction indicated by arrow (2), remove the shaft. 3. Pull off the inner handle, and remove the door lock knob cable and inner handle cable. 4. Install in the reverse order of removal. A6E771458330W01 A6E7714W010 End Of Sie HANDLE REMOVAL REGULATOR 1. Remove the regulator handle clip using a rag as shown.
POWER WINDOW SYSTEM POWER WINDOW SYSTEM INITIAL SETTING A6E771666350W01 Note • A driver side window will not fully close automatically under following the conditions: The battery has been disconnected during vehicle maintenance or for other reasons. The power window main switch connector, or driver-side power window motor connector has been disconnected. • Carry out the following procedure to resume operation: 1. Turn the ignition switch to the ON position. 2.
POWER WINDOW SYSTEM DOOR GLASS POSITION CHANGE PROCEDURE A6E771666350W03 Note • After performing the following procedure, verify that the two-step down function operates normally and the door glass position has changed. If the two-step down function does not operate or the door glass position has not changed, the procedure was not performed properly. Repeat the procedure from the beginning.
POWER WINDOW SYSTEM POWER WINDOW SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front door trim or rear door trim. 3. Remove the screws, then the power window switch. 4. Install in the reverse order of removal.
POWER WINDOW SYSTEM POWER WINDOW MAIN SWITCH INSPECTION A6E771666350W05 Drivers side 1. Remove the driver-side front door trim. 2. Connect the power window main switch connector. 3. Measure the voltage at the power window main switch terminals as indicated below. 4. Disconnect the power window main switch connector before inspecting for continuity at terminals 1M (1J*2) and 1F (1L*2). • If not as specified, inspect the parts listed under Action.
POWER WINDOW SYSTEM Except drivers side 1. Turn the power-cut switch to UNLOCK. 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. • If not as specified, replace the power window main switch.
POWER WINDOW SYSTEM POWER WINDOW SUBSWITCH INSPECTION 1. Inspect for continuity between the power window subswitch terminals. • If not as specified, replace the power window subswitch. A6E771666370W01 A6E7716W011 A6E7716W013 End Of Sie POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the front door glass/rear door glass. Remove the front door speaker/rear door speaker. Remove the power window motor. Remove the nuts.
POWER WINDOW SYSTEM 7. Remove the power window regulator from the speaker installation hole. 8. Install in the reverse order of removal. A6E7716W007 End Of Sie POWER WINDOW MOTOR REMOVAL/INSTALLATION 1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the front door trim or rear door trim. Disconnect the power window motor connector. Remove the bolts. Remove the power window motor from the power window regulator drum. 6. Install in the reverse order of removal.
POWER WINDOW SYSTEM, POWER DOOR LOCK SYSTEM Except Driver's Side 1. Apply battery positive voltage to the power window motor terminals and inspect the operation of the power window motor. • If not as specified, replace the power window motor. Motor operation UP DOWN Terminal F GND B+ E B+ GND A6E7716W010 End Of Sie POWER DOOR LOCK SYSTEM FRONT DOOR LOCK ACTUATOR INSPECTION Door Lock Actuator 1. Disconnect the front door lock actuator connector. 2.
POWER DOOR LOCK SYSTEM Door Lock-link Switch 1. Disconnect the front door lock actuator connector. 2. Inspect for continuity between the door lock-link switch terminals using an ohmmeter. • If not as specified, replace the front door lock actuator. A6E7718W008 A6E7718W012 Door Key Cylinder Switch 1. Disconnect the front door lock actuator connector. 2. Inspect for continuity between the door lock-link switch terminals using an ohmmeter. • If not as specified, replace the front door lock actuator.
POWER DOOR LOCK SYSTEM REAR DOOR LOCK ACTUATOR INSPECTION Door Lock Actuator 1. Disconnect the front door lock actuator connector. 2. Apply battery positive voltage to the front door lock actuator terminals and inspect the operation of the front door lock actuator. • If not as specified, replace the front door lock actuator.
POWER DOOR LOCK SYSTEM LIFTGATE LOCK ACTUATOR INSPECTION 1. Disconnect the liftgate lock actuator connector. 2. Apply battery positive voltage to the liftgate lock actuator terminals and inspect the operation of the liftgate lock actuator. • If not as specified, replace the liftgate lock. Actuator operation Lock Unlock A6E771862310W01 Connection B+ A B GND B A A6E7718W016 End OfLOCK Sie TIMER UNIT REMOVAL/INSTALLATION DOOR 1. 2. 3. 4. Disconnect the negative battery cable.
POWER DOOR LOCK SYSTEM DOOR LOCK TIMER UNIT INSPECTION A6E771867830W02 1. Measure the voltage at the door lock timer unit terminals (other than terminal 1E and 2W) as indicated below. • If not as specified, inspect the parts listed under Action. 2. Disconnect the negative battery cable. 3. Disconnect the door lock timer unit connector and inspect for continuity between terminal 1E or 2W and the bracket. 4. Inspect for continuity at terminal 1E and 2W as indicated below. 5.
POWER DOOR LOCK SYSTEM Terminal Signal Connected to 2D 2E - - 2F 2G 2H 2I Key reminder switch Liftgate Door switch open/closed - Hazard 2J*1 Security light output 2K Door open/ closed 2L 2N 2M 2O - 2P*2 Theftdeterrent alarm control - Flasher unit Instrument cluster Door switch Theft-deterrent control module 2Q Lock input 2R Unlock input Door lock-link switch 2S 2T 2U 2V 2W *1 *2 Key reminder switch 2X Door lock-link switch Voltage (V)/ Continuity B+ • Other Below 1.
POWER DOOR LOCK SYSTEM End OfLOCK Sie TIMER UNIT ID CODE CHANGE DOOR A6E771801097W01 Note • When programming the ID code into a door lock timer unit, verify that other transmitters are not being operated in the vicinity.
POWER DOOR LOCK SYSTEM TRANSMITTER BATTERY REPLACEMENT 1. Insert a small screwdriver into the slot and gently pry open the transmitter. A6E771800110W01 A6E7718W001 2. Press the portion of the battery indicated by A and remove the battery. 3. Install a new battery (CR2025) into the front portion of the holder with the positive pole (+) facing up. Press on the B portion of the battery to set the battery. A6E7718W002 4. Align the front and back covers and snap the transmitter shut.
POWER DOOR LOCK SYSTEM TRANSMITTER BATTERY INSPECTION A6E771800110W02 Caution • Since the battery voltage does not drop fully if the button is pushed for only 4 seconds or less, it can not be properly examined to see whether it is good or bad. Always push the button for 5 seconds. Note • A correct measurement can not be obtained if the battery temperature is low.
TRUNK LID TRUNK LID TRUNK LID REMOVAL/INSTALLATION A6E772052610W01 Warning • Removing the stay damper without supporting the trunk lid can be dangerous. The trunk lid may fall and injure you. Open the trunk lid fully and support it before removing the stay damper. 1. Disconnect the negative battery cable. 2. Disconnect the trunk lid harness connector, pull the trunk lid harness out from the cabin. A6E7720W001 3. Disconnect the hooks, which secure the trunk lid harness to the trunk lid hinge.
TRUNK LID 6. Remove the nuts, then remove the trunk lid. 7. Remove the bolts, then remove the trunk lid hinge. 8. Install in the reverse order of removal. 9. Adjust the trunk lid. (See S41 TRUNK LID ADJUSTMENT.) A6E7720W007 End Of Sie TRUNK LID DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the trunk lid trim. To remove the trunk lid outer handle and trunk lid key cylinder, remove the rear finisher. Disassemble in the order indicated in the table.
TRUNK LID TRUNK LID ADJUSTMENT 1. Measure the gap and height between the front door and the body. 2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation screws, and reposition the door. A6E772052610W03 Clearance a: 2.54.5 mm {0.100.18 in} b: -1.01.0 mm {-0.040.04 in} c: 4.08.0 mm {0.160.31 in} 3. Tighten the bolts or screws.
LIFTGATE LIFTGATE LIFTGATE REMOVAL/INSTALLATION A6E772262010W01 Warning • Removing the stay damper without supporting the liftgate can be dangerous. The liftgate may fall and injure you. Open the liftgate fully and support it before removing the stay damper. 1. Disconnect the negative battery cable. 2. Remove the liftgate lower upper trim. 3. Press the liftgate harness connector's bracket, which is attached to the liftgate, to the (1) direction shown in the figure, and then detach the fit.
LIFTGATE 9. To remove the stay damper, remove the bolt B. A6E7722W001 10. Install in the reverse order of removal.
LIFTGATE LIFTGATE DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. Disconnect the negative battery cable. Remove the liftgate lower trim. To remove the liftgate outer handle and liftgate key cylinder, remove the rear finisher. To remove the stud ball, separate the stud ball and the stay damper. Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly. A6E772262010W02 .
LIFTGATE LIFTGATE ADJUSTMENT 1. Measure the gap and height between the liftgate and the body. 2. If not as specified, loosen the liftgate hinge installation bolts or the liftgate striker installation screws, and reposition the liftgate. A6E772262010W03 Clearance a: 3.07.0 mm {0.120.28 in} b: -1.03.4 mm {-0.04013 in} c: 2.85.2 mm {0.110.24 in} d: -1.21.2 mm {0.050.05 in} e: 2.85.8 mm {0.110.22 in} f:4.08.0 mm {0.160.31 in} 3. Tighten the bolts or screws.
FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER REMOVAL/INSTALLATION A6E772456890W01 1. To remove the fuel-filler lid opener, remove the left side trunk side trim (4SD) or trunk side lower trim (5HB). 2. To remove the fuel-filler lid opener cable, perform the following and turn over the floor covering. (1) Remove the driver-side front seat. (2) Remove the driver-side front scuff plate. (3) Remove the driver-side rear scuff plate.
BUMPER BUMPER FRONT BUMPER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 5 6 A6E772650031W01 Screw A Fastener A Screw B Bolt Fastener B Front bumper (See S47 Front Bumper Removal Note) (See S48 Front Bumper Installation Note) 3. Install in the reverse order of removal. A6E7726W003 Front Bumper Removal Note 1. Pull the front bumper ends (wheel arch) outward to disengage from the bumper slider.
BUMPER Front Bumper Installation Note 1. Spread the front bumper ends (wheel arches) apart. 2. Attach the front bumper to the body. 3. Press the front bumper connection portion into the body to engage with the bumper slider. End Of Sie FRONT BUMPER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 1 2 A6E772650031W02 Front bumper mesh Front bumper fascia 2. Assemble in the reverse order of disassembly. A6E7726W004 End Of Sie BUMPER REINFORCEMENT REMOVAL/INSTALLATION 1. 2. 3. 4.
BUMPER REAR BUMPER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the rear combination light. 3. Remove in the order indicated in the table. 1 2 3 4 5 6 7 8 9 10 A6E772650221W01 Screw A Screw B Screw C Fastener A Bolt A Fastener B Rear bumper (See S49 Rear Bumper Removal Note) (See S49 Rear Bumper Installation Note) Refractor (See S50 Refractor Removal Note) Bolt B Rear bumper reinforcement 4. Install in the reverse order of removal. A6E7726W001 Rear Bumper Removal Note 1.
BUMPER, EXTERIOR ATTACHMENT Refractor Removal Note 1. Lift the refractor up in the direction of the arrow, then unhook it from the rear bumper. A6E7726W002 End Of Sie EXTERIOR ATTACHMENT RADIATOR GRILLE REMOVAL/INSTALLATION 1. Remove the screws. 2. Press clip A in the direction of the arrow, pll the radiator grille outward and remove from the front bumper. 3. Install in the reverse order of removal. A6E772850710W01 A6E7728W005 End OfGRILLE Sie COWL REMOVAL/INSTALLATION A6E772850790W01 1.
EXTERIOR ATTACHMENT FRONT FLAP REMOVAL/INSTALLATION 1. Remove the screws and fastner. 2. Remove the front flap. 3. Install in the reverse order of removal. A6E772851840W01 A6E7728W011 End OfFLAP Sie REMOVAL/INSTALLATION REAR 1. Remove the screws. 2. Remove the rear flap. 3. Install in the reverse order of removal. A6E772851940W01 A6E7728W012 End OfDOOR Sie GARNISH REMOVAL REAR A6E772850030W01 1. Disengage the door garnish clips using a fastener remover. 2.
EXTERIOR ATTACHMENT REAR DOOR GARNISH INSTALLATION A6E772850030W02 Note • Double-sided adhesive tape has already been attached to the new rear door garnish. Warning • Using a razor with bare hands can cause injury. Always wear gloves when using a razor. 1. When installing a new rear door garnish, follow the procedure below: (1) Remove the adhesive remaining on the body using razor. (2) Remove any grease or dirt from the adhesion surface of the body. 2.
EXTERIOR ATTACHMENT SIDE PROTECTOR INSTALLATION A6E772850680W02 1. Remove the adhesive remaining on the side protector (if it will be reused) and the body using a razor. 2. Remove any grease or dirt from the adhesion surface of the side protector (if it will be reused) and the body. 3. Attach double-sided adhesive tape to the side protector as shown (if it will be reused). Clearance a: 30.0 mm {1.18 in} b: 3.0 mm {0.11 in} c: 12.0 mm {0.47 in} d: 3.0 mm {0.11 in} e: 3.0 mm {0.11 in} f: 1.03.0 mm {0.040.
EXTERIOR ATTACHMENT REAR FINISHER REMOVAL/INSTALLATION 1. 2. 3. 4. Remove the trunk lid trim (4SD). Remove the liftgate lower trim (5HB). Remove the nuts. Pull the rear finisher toward you, then disengage clip A from the body. 5. Install in the reverse order of removal. A6E772850850W01 A6E7728W002 End OfSPOILER Sie REAR REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. Remove the trunk lid trim. (4SD) Remove the liftgate lower trim. (5HB) Remove the bolts. Disconnect the high-mount brake light connector.
MOLDING MOLDING FRONT BELTLINE MOLDING REMOVAL A6E773050640W01 Note • When removing the front beltline molding, the clip may be damaged. If the clip is damaged, replace it with a new one. 1. Pull the A section upward and remove the clip. 2. Rotate the B section of the front beltline molding in direction (2), along the direction (1) shown in the figure and remove it from the body. A6E7730W001 End Of Sie FRONT BELTLINE MOLDING INSTALLATION 1. Press the clip into the body. 2.
MOLDING REAR BELTLINE MOLDING REMOVAL A6E773050660W01 Note • When removing the rear beltline molding, the clip may be damaged. If the clip is damaged, replace it with a new one. 1. Pull the A section upward and remove the clip. 2. Rotate the B section of the front beltline molding in direction (2), along the direction (1) shown in the figure and remove it from the body. 3. Pull the C section upward and remove the clip. Then remove the front beltline molding.
MOLDING ROOF MOLDING REMOVAL 1. Detach the clips which secure A and B sections of roof molding, using a screwdriver or equivalent tool. 2. While pulling the roof molding up, detach the fit for the T stat of the A section and the roof molding and then remove the roof molding. A6E773050620W01 A6E7730W007 End OfMOLDING Sie ROOF INSTALLATION 1. Attach the roof molding to the T stud at the A section. 2.
OUTSIDE MIRROR OUTSIDE MIRROR POWER OUTSIDE MIRROR REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. Disconnect the negative battery cable. Remove the inner garnish. Remove the front door trim. Disconnect the power outside mirror connector. Remove the screws and the mirror retention clips. Remove the power outside mirror. Install in the reverse order of removal. A6E773269110W01 A6E7732W006 End Of Sie POWER OUTSIDE MIRROR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table.
OUTSIDE MIRROR Cover Disassembly Note 1. Pull off the mirror holder tab with a screwdriver and press the mirror cover tab downward. A6E7732W004 Outside Mirror Glass Assembly Note 1. Press the mirror into the base so that the pin does not dislodge. S A6E7732W005 End Of Sie POWER OUTSIDE MIRROR INSPECTION 1. Disconnect the power outside mirror connector. 2. Apply battery positive voltage to the power outside mirror terminals and inspect the operation of the power outside mirror.
OUTSIDE MIRROR POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front door trim. 3. Remove the screws and the power outside mirror switch. 4. Install in the reverse order of removal. A6E773266600W01 A6E7732W008 End Of Sie POWER OUTSIDE MIRROR SWITCH INSPECTION 1. Inspect for continuity between the power outside mirror switch terminals using an ohmmeter. • If not as specified, replace the power outside mirror switch.
REARVIEW MIRROR REARVIEW MIRROR REARVIEW MIRROR REMOVAL 1. Insert a screwdriver between the mirror and the base. 2. Push the base pin down to remove the rearview mirror. A6E773469220W01 A6E7734W001 End Of Sie MIRROR INSTALLATION REARVIEW 1. Install the rearview mirror onto the base. A6E773469220W02 S A6E7734W002 End OfREMOVAL Sie BASE 1. Remove the rearview mirror. 2. Wind each end of a wire around a bar. A6E773469240W01 Warning • Using a SST (piano wire) with bare hands can cause injury.
REARVIEW MIRROR BASE INSTALLATION 1. Cut away all of the original sealant using a razor. 2. Clean and degrease the ceramic coating on the glass and the base. 3. Apply primer to the bonding area of the glass and the base. A6E773469240W02 Caution • Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass. 4. Apply a height of 3.0 mm {0.12 in} sealant to the base. Note • Use only glass primer on the glass, and body primer on the base.
REAR WINDOW DEFROSTER REAR WINDOW DEFROSTER FILAMENT REPAIR 1. Use isopropyl alcohol to clean around the damaged section of the filament. 2. Attach tape above and below the damaged section of the filament. 3. Using a small brush or marking pen, repair the filament with silver paint or equivalent. 4. After 23 minutes, carefully remove the tape without disturbing the repaired area. Caution • Do not use the rear window defroster until the paint is completely dry.
WINDOW GLASS WINDOW GLASS WINDSHIELD REMOVAL 1. 2. 3. 4. 5. 6. Remove the rearview mirror. Remove the cowl grille. Remove the headliner. Apply protective tape along the edge of the body to protect it from damage. Apply protective tape to the dashboard to protect it from damage. Cut the lip of the windshield molding using a razor. A6E773863900W01 Warning • Using a razor with bare hands can cause injury. Always wear gloves when using a razor. Note • The windshield molding is a replacement part.
WINDOW GLASS 2. Pass the SST (piano wire) through the hole. Warning • Using a SST (piano wire) with bare hands can cause injury. Always wear gloves when using a SST (piano wire). 3. Wind each end of the SST (piano wire) around a bar. Note • Use a long sawing action to spread the work over the whole length of the SST (piano wire) to prevent it from breaking. A6E7738W008 4. Working with another person, saw through the sealant around the edge of the glass. 5. Remove the windshield. 6.
WINDOW GLASS 4. If installing reused glass, install pins at the ceramic void on the upper part of the windshield. 5. If installing reused glass, align the front windshield molding marking and the center of the upper section of the windshield, then install the molding to the winshield. 6. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes.
WINDOW GLASS 9. Verify that the gap of the A pillar part as shown the figure. A6E7738W003 10. Keeping the measurement of the molding lip gap within specification, press completely along the perimeter of the glass. 11. Install the seaming welt. 12. Install the cowl grille. 13. Install the headliner 14. Install the interior light. (See T48 FRONT MAP LIGHT REMOVAL/INSTALLATION.) 15. Allow the sealant to harden completely.
WINDOW GLASS REAR WINDOW GLASS REMOVAL 1. For the 4SD, remove the following parts: (1) Remove the headliner. (2) Remove the rear package trim. 2. For the 5HB, remove the following parts. (1) Remove the rear wiper arm and blade. (2) Remove the liftgate lower trim. 3. Apply protective tape along the edge of the body to protect it from damage. 4. Cut the lip of the rear window molding using a razor. A6E773863931W01 Warning • Using a razor with bare hands can cause injury.
WINDOW GLASS Reusing Glass Note • Before removing the rear window glass from the body, mark the position of the glass by affixing tape to the glass and body panel. 1. Make a hole through the sealant, avoiding pins, from the inside of the vehicle using an awl. A6E7738W010 2. Pass the SST (piano wire) through the hole. Warning • Using a SST (piano wire) with bare hands can cause injury. Always wear gloves when using a SST (piano wire). 3. Wind each end of the SST (piano wire) around a bar.
WINDOW GLASS 4. Working with another person, saw through the sealant around the edge of the glass. 5. Remove the rear window glass. 6. Remove the pins from the glass. 7. Remove the rear window molding from the glass. A6E7738W021 End OfWINDOW Sie REAR GLASS INSTALLATION A6E773863931W02 Caution • To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened. 1.
WINDOW GLASS 5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes. Caution • Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
WINDOW GLASS 6. Apply urethane to the area of the glass surface as shown in the figure. A6E7738W020 7. Set the position of the front windshield glass and insert a pin into the body. Install the glass. A6E7738W018 8. Verify that the gap of the upper part is 7.3 mm {0.29 in} and the A pillar part is 6.8 mm {0.27 in}.
WINDOW GLASS 9. Keeping the measurement of the molding lip gap within specification, press completely along the perimeter of the glass. 10. For the 4SD, install the following parts: (1) Install the headliner. (2) Install the rear package trim. 11. For the 5HB, install the following points. (1) Install the rear wiper motor. (2) Install the liftgate lower trim. 12. Allow the sealant to harden completely.
SLIDING SUNROOF SLIDING SUNROOF DEFLECTOR REMOVAL/INSTALLATION 1. 2. 3. 4. Fully open the glass panel. Remove the headliner. Remove the screws. Disengage the hooks. (1) Press the rear end of each hook. (2) After sliding the hooks rearward, press them upward. 5. Remove the deflector. 6. Install in the reverse order of removal. A6E774069880W01 A6E7740W003 End Of PANEL Sie GLASS REMOVAL/INSTALLATION 1. Fully close the glass panel. 2. Fully open the sunshade. 3.
SLIDING SUNROOF End Of Sie GLASS PANEL ADJUSTMENT 1. Fully close the glass panel. 2. Measure the gap and height between the glass panel and body. 3. If not as specified, loosen the glass panel installation screws and reposition the glass panel. A6E774069810W02 Clearance a: -0.81.2 mm {-0.0320.047 in} b: 0 mm {0 in} 4. Tighten the installation screws. 5. Insert a prepaid card between the weatherstrip and the body of the vehicle.
SLIDING SUNROOF End OfDRAIN Sie HOSE REMOVAL REAR 1. Remove the headliner. 2. Remove the trunk side trim. (4SD) 3. Remove the trunk side upper trim and trunk side trim. (5HB) 4. Disconnect the rear drain hose from the sunroof frame. 5. Remove the rear drain hose from the clips. 6. Pull the rear drain hose into the room side. 7. Remove the rear drain hose.
SLIDING SUNROOF 6. Remove the bolt B and nuts, and then remove the sunroof unit. 7. Install in the reverse order of removal. 8. Adjust the glass panel. (See S75 GLASS PANEL ADJUSTMENT.) A6E7740W005 End Of SieUNIT DISASSEMBLY/ASSEMBLY SUNROOF 1. 2. 3. 4. 5. A6E774069850W02 Disconnect the negative battery cable. Remove the deflector. Remove the glass panel. Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly. S A6E7740W001 .
SLIDING SUNROOF Slider Disassembly Note 1. Remove the screw. 2. Slide the slider rearward, and remove it from the sunroof frame. A6E7740W012 Guide Disassembly Note 1. Slide the guide rearward, and remove it from the sunroof frame. A6E7740W013 Decoration Link Assembly Note 1. Set the pin in the decoration link. A6E7740W014 Guide Assembly Note 1. Move the guide by hand until it comes to the front stopper. 2. Move the guide by hand until center of pin comes between mark A and B.
SLIDING SUNROOF SUNROOF MOTOR REMOVAL 1. 2. 3. 4. Disconnect the negative battery cable. Remove the headliner. Disconnect the connector. Remove the screws, and then remove the sunroof motor. A6E774069870W01 A6E7740W002 End Of SieMOTOR INSTALLATION SUNROOF 1. 2. 3. 4. 5. 6. 7. 8. Connect the sunroof motor connector. Connect the sunroof switch connector. Connect the negative battery cable. Turn the ignition switch to ON position. Press the CLOSE side of the slide switch until the sunroof motor stops.
SLIDING SUNROOF Limit Switch 1. Remove the headliner. (See S96 HEADLINER REMOVAL/INSTALLATION.) 2. Verify the glass panel position. 3. Disconnect the connector. 4. Inspect for continuity between the sunroof motor terminals using an ohmmeter. • If not as specified, replace the sunroof motor. A6E7740W021 A6E7740W020 End Of SieRELAY INSPECTION SUNROOF A6E774069873W01 Note • Sunroof relay is built in the sunroof motor. 1. 2. 3. 4. Remove the headliner. (See S96 HEADLINER REMOVAL/INSTALLATION.
SLIDING SUNROOF Terminal Signal Connected to 1F Slide open Sunroof switch 1G Sunroof relay GND ground 1H Tilt up Test condition Sunroof is fully opening. 2A Slide close/ tilt up Sunroof switch Sunroof motor Other Under any condition: inspect for continuity to ground. Sunroof is tilting up. (Including position when fully closed) Other Sunroof is opening/tilting down. Sunroof is closing/tilting up. Other 2B Slide open/tilt Sunroof motor down Sunroof is opening/tilting down.
DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE DASHBOARD REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. A6E774255100W01 Disconnect the negative battery cable. Remove the glove compartment. Remove the console. Remove the meter hood. Remove the instrument cluster. Remove the column cover. Remove the lower panel. Remove the steering shaft. Remove the A-pillar trims. Remove the front scuff plates. Remove the front side trims. Remove the side panels.
DASHBOARD AND CONSOLE DASHBOARD DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. A6E774255100W02 Remove the passenger-side air bag module. Remove the ventilator grilles. Remove the audio unit. Remove the climate control unit. Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly. S A6E7742W003 . 1 2 Dashboard harness Dashboard member End Of Sie REMOVAL/INSTALLATION SIDE PANEL 1. Disengage clips using a tape-wrapped flathead screwdriver. 2.
DASHBOARD AND CONSOLE COLUMN COVER REMOVAL/INSTALLATION 1. Detach the fit of the upper column cover from the meter hood rubber. 2. Remove the upper column cover. 3. Remove the ignition key illumination. 4. Remove the screws. 5. Remove the lower column cover. 6. Install in the reverse order of removal. A6E774260200W01 A6E7742W008 End Of Sie METER HOOD REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the meter hood toward you, then detach the column cover. 3. Install in the reverse order of removal.
DASHBOARD AND CONSOLE CENTER BOX REMOVAL/INSTALLATION 1. 2. 3. 4. Disconnect the negative battery cable. Remove the center panel module. Remove the screws. Pull the center box forward, then disengage the tabs 5. Disconnect the LDC unit connector. 6. Install in the reverse order of removal. A6E774264030W01 A6E7742W012 End Of Sie GLOVE COMPARTMENT REMOVAL/INSTALLATION 1. Pull the stay damper to the direction shown in the figure. Then detach the fit for the glove compartment from the stay damper.
DASHBOARD AND CONSOLE CONSOLE REMOVAL/INSTALLATION 1. For MT vehicle, remove the shift lever knob. 2. Remove the cup holder panel using a tapewrapped screwdriver. 3. Remove the boot panel using a tape-wrapped screwdriver, disconnect the cigarette lighter connector, and remove the front ashtray illumination. 4. Remove the bolts. 5. Install in the reverse order of removal. A6E774264270W01 A6E7742W011 End Of SieDISASSEMBLY/ASSEMBLY CONSOLE 1. Disassemble in the order indicated in the table.
TRIM TRIM A-PILLAR TRIM REMOVAL 1. 2. 3. 4. Turn the seaming welt over. Disengage clips A using a fastener remover. Pull the A-pillar trim, then disengage clip B (1). Pull the A-pillar trim upward, then disengage clip B from the A-pillar trim (2). A6E774468160W01 A6E7744W023 5. Pull clip B out, then rotate 45° . 6. Remove clip B from the grommet by pulling it toward you. S A6E7744W024 End Of SieTRIM INSTALLATION A-PILLAR 1. Cut A-pillar trim tab A to the same length as tab B. 2.
TRIM B-PILLAR LOWER TRIM REMOVAL/INSTALLATION 1. Remove the front scuff plate. 2. Remove the rear scuff plate. 3. Pull the area marked A, then remove one side of the B-pillar lower trim. 4. Pull the B-pillar lower trim, then remove the pin from the body. 5. Remove the B-pillar lower trim. 6. Install in the reverse order of removal. A6E774468220W01 A6E7744W021 End Of SieUPPER TRIM REMOVAL/INSTALLATION B-PILLAR 1. 2. 3. 4. Remove the upper anchor of the front seat belt. Remove the B-pillar lower trim.
TRIM FRONT SCUFF PLATE REMOVAL/INSTALLATION 1. Pull the front scuff plate upward, then disengage clips B, pins C, D and hooks E from the body, and remove the front scuff plate. 2. Install in the reverse order of removal. A6E774468710W01 A6E7744W017 End OfSCUFF Sie PLATE REMOVAL/INSTALLATION REAR 1. Pull the rear scuff plate upward, then disengage clips A, pin B, and hooks C from the body, and remove the rear scuff plate. 2. Install in the reverse order of removal.
TRIM FRONT DOOR TRIM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Open the cap using a small screwdriver, then remove the screw. 3. Remove the inner handle cover. 4. Remove the inner garnish. A6E774468420W01 A6E7744W009 5. Remove the cover, then remove screw A. 6. Remove the lens cover, then remove screw B. 7. Disengage clips A from the front door using a fastener remover. 8. Pull the front door trim upward, then disengage hooks B from the front door. 9.
TRIM 7. Pull the rear door trim upward, then disengage hooks B from the rear door. 8. Disconnect the power window subswitch connector if equipped. 9. Remove the rear door trim. 10. Remove the switch panel from the rear door trim. 11. Install in the reverse order of removal. A6E7744W011 End Of Sie TRIM REMOVAL/INSTALLATION TIRE HOUSE 4SD 1. Remove the rear scuff plate. 2. Remove the rear seat side. 3. Remove the fastener. 4.
TRIM REAR PACKAGE TRIM REMOVAL/INSTALLATION 1. 2. 3. 4. Remove the high-mount brake light. Fold the rear seat back. Remove the fasteners. Pull the rear package trim upward, then disengage the clips from the body. 5. Disengage the hooks, then remove the rear package trim. 6. Install in the reverse order of removal. A6E774468320W01 A6E7744W026 End Of Sie TRUNK SIDE TRIM REMOVAL/INSTALLATION 4SD 1. Remove the trunk end trim. 2. Remove the fasteners, then remove the trunk side trim. 3.
TRIM TRUNK SIDE UPPER TRIM REMOVAL/INSTALLATION 1. 2. 3. 4. 5. Disconnect the negative battery cable. (LH only) Remove the tire house trim. Remove the rear seat remote lever. Remove the screw. Pull the trunk side upper trim toward you, then disengage clips A from the body. 6. Disconnect the cargo compartment light connector. (LH only) 7. Install in the reverse order of removal. A6E774468860W02 A6E7744W006 End Of Sie TRUNK LID TRIM REMOVAL/INSTALLATION 1.
TRIM 5HB 1. Pull the trunk end trim upward, then disengage clips A, pins B, and hooks. 2. Remove the trunk end trim. 3. Install in the reverse order of removal. A6E7744W013 End Of SieUPPER TRIM REMOVAL/INSTALLATION LIFTGATE 1. Pull the liftgate upper trim toward you, then disengage clips A, and pin B from the body. 2. Remove the liftgate upper trim. 3. Install in the reverse order of removal. A6E774468930W01 A6E7744W002 End Of SieSIDE TRIM REMOVAL/INSTALLATION LIFTGATE 1.
TRIM 3. Pull the liftgate side trim toward you, then disengage clips A, pin B and the strap hanger from the body and pin B, hook C, D from the liftgate lower trim. 4. Remove the liftgate side trim. 5. Remove the hanger strap from the liftgate side trim. 6. Install in the reverse order of removal. A6E7744W004 End Of SieLOWER TRIM REMOVAL/INSTALLATION LIFTGATE 1. Remove the liftgate upper trim. 2. Remove the liftgate side trim. 3. Pull the handle toward you, then remove the handle. 4.
HEADLINER HEADLINER HEADLINER REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. A6E774668030W01 Disconnect the negative battery cable. Turn the seaming welt and weatherstrip over. Remove the sunroof seaming welt. (vehicles with sunroof only) Remove the A-pillar trims. Remove the B-pillar upper trims. Remove the C-pillar trims. Remove the front and rear map light. (See T48 FRONT MAP LIGHT REMOVAL/INSTALLATION.) (See T49 REAR MAP LIGHT REMOVAL/INSTALLATION.) Remove the sunvisors.
HEADLINER SHOCK ABSORBING PAD REMOVAL/INSTALLATION 1. Remove the headliner. 2. Remove the fastener, then remove the shock absorbing pad. 3. Install in the reverse order of removal. A6E774668H10W01 A6E7746W003 End Of Sie ASSIST HANDLE REMOVAL/INSTALLATION 1. Insert a screwdriver into the assist handle notch and remove the assist handle cover. A6E774669440W01 S A6E7746W001 2. Pull the assist handle forward you, then remove the assist handle. 3. Install in the reverse order of removal.
HEADLINER SUNVISOR REMOVAL/INSTALLATION 1. Remove the screws, then the sunvisor. A6E774669270W01 A6E7746W005 2. Disengage the center adapter (sunvisor stopper) from the body using a fastener remover. 3. Install in the reverse order of removal.
FLOOR COVERING FLOOR COVERING FRONT FLOOR COVERING REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Disconnect the negative battery cable. Remove the front seats. (See S105 FRONT SEAT REMOVAL/INSTALLATION.) Remove the rear seat. Remove the front scuff plates. Remove the rear scuff plates. Remove the console. Remove the front side trims. Remove the B-pillar lower trims. Remove the lower anchor of the front seat belt installation bolts. Remove the tire house trim.
SEAT BELT SEAT BELT FRONT SEAT BELT REMOVAL/INSTALLATION A6E775057630W01 Warning • Handling the front seat belt (pre-tensioner seat belt) improperly can accidentally deploy the pretensioner, which may seriously injure you. Read SERVICE WARNINGS before handling the front seat belt. (See T117 SERVICE WARNINGS.) Warning • The side air bag sensor is attached to the lower part of the B-pillar.
SEAT BELT REAR SIDE SEAT BELT REMOVAL/INSTALLATION A6E775057730W01 Caution • The ELR has a spring that will unwind if the retractor's cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the retractor. 4SD 1. Fold the rear seat back. 2. Remove the rear side seats. 3. Remove the rear package trim. 4. Remove the bolts. 5. Remove the rear seat belt. 6. Install in the reverse order of removal.
SEAT BELT 5HB 1. Remove the rear scuff plate. 2. Remove the tire house trim. 3. Remove the trunk side upper trim. 4. Remove the C-pillar trims. 5. Remove the bolts. 6. Remove the rear center seat belt. 7. Install in the reverse order of removal. A6E7750W004 End Of Sie FRONT BUCKLE REMOVAL/INSTALLATION 1. Perform the following procedure for vehicles with seat belt warning. (1) Disconnect the negative battery cable. (2) Remove the front seat. (3) Disconnect the buckle switch connector. 2.
SEAT BELT SEAT BELT INSPECTION Belt 1. Confirm that the seat belt is installed correctly. 2. Inspect the seat belt for damage and deformation of metal parts. • If any damage is found, replace as necessary. A6E775057000W01 ELR 1. Verify that the belt can be pulled out smoothly, and that it moves smoothly when wound. • If not as specified, replace the seat belt. 2. Verify that the retractor locks when the belt is quickly pulled. • If not as specified, replace the seat belt. 3. Remove the retractor.
SEAT BELT BUCKLE SWITCH INSPECTION Driver's Seat 1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch terminals using an ohmmeter. • If not as specified, replace the front buckle. A6E775057620W02 A6E7750W009 A6E7750W010 End OfRESTRAINT Sie CHILD SEAT ANCHOR REMOVAL/INSTALLATION 1. Remove the cover. 2. Remove the bolt and child restraint seat anchor. 3. Install in the reverse order of removal.
SEAT SEAT FRONT SEAT REMOVAL/INSTALLATION A6E775257100W01 Warning • Handling the front seat (side air bag) improperly can accidentally deploy the side air bag, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the front seat. (See T117 SERVICE WARNINGS.) 1. Turn the ignition switch to the LOCK position. 2. Disconnect the negative battery cable and wait for more than 1 minute. 3. Remove in the order indicated in the table. 1 2 3 Connector Cover Front seat 4.
SEAT FRONT SEAT DISASSEMBLY/ASSEMBLY A6E775257100W02 Warning • Handling the front seat (side air bag) improperly can accidentally deploy the side air bag, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the front seat. (See T117 SERVICE WARNINGS.) 1. 2. 3. 4. Disconnect the negative battery cable and wait for more than 1 minute. Remove the side air bag module. (See T121 SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) Disassemble in the order indicated in the table.
SEAT Driver's Seat (Power Seat) S A6E7752W027 . 1 2 3 4 5 6 7 8 9 Headrest Lumber support lever (See S109 Lumber support lever disassembly note.) Slider and lifter switch knob Recliner switch knob Side cover (See S109 Side cover disassembly note.) Power seat switch Reverce cover Front cover No. 1 Front cover No. 2 10 11 12 13 14 15 16 17 18 19 20 Front buckle Pole guide Seat back trim Seat warmer unit (European (L.H.D.) specs.
SEAT Passenger's Seat Warning • Do not disassemble the seat cushion. Doing so will necessitate reassembly which may damage or press the occupancy sensor. This will cause the misoperation of the air bag system, which may seriously injure you. A6E7752W003 . 1 2 3 4 5 6 7 Headrest Recliner lever Side cover (See S109 Side cover disassembly note.) Reverse cover Front buckle Pole guide Seat back trim S108 8 9 10 11 12 13 14 15 Seat warmer unit (European (L.H.D.) specs.
SEAT Lumber support lever disassembly note 1. Remove the pin from the lumber support lever installation part with rag. A6E7752W018 Recliner dial disassembly note 1. Remove the pin from the recliner dial installation part with rag. A6E7752W019 Side cover disassembly note 1. Remove the screws. 2. Disengage the clips. 3. Lift the side cover up in the direction of the arrow, then unhook it from slide adjuster.
SEAT End OfSEAT Sie REMOVAL/INSTALLATION REAR A6E775257200W01 4SD 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. .
SEAT 5HB 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. . S A6E7752W012 1 Remote wire (See S111 Remote wire removal note.) 2 Rear seat (See S112 Rear seat removal note.) Remote wire removal note 1. Turn over the trunk floor mat. 2. Remove the case. 3. Remove the remote wire.
SEAT Rear seat removal note 1. Remove the front hinge installation bolts. 2. Lift the rear seat cushion, then remove the rear hinge installation bolts. A6E7752W013 End OfSEAT Sie DISASSEMBLY/ASSEMBLY REAR A6E775257200W02 4SD 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. .
SEAT 9 10 11 Armrest pad Pole guide Seat back trim 12 13 Seat back pad Seat back frame 5HB 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. .
SEAT End Of Sie REMOTE HANDLE LEVER REMOVAL/INSTALLATION 4SD 1. To remove the remote wire, remove the trunk side trim. 2. Remove in the order indicated in the table. 1 2 3 A6E775200166W01 Remote handle lever Remote wire Remote catch 3. Install in the reverse order of removal. A6E7752W005 5HB 1. To remove the remote wire, remove the trunk side upper trim and trunk side trim. 2. Remove in the order indicated in the table. 1 2 3 Remote handle lever Cover Remote wire 3.
SEAT SEAT BACK STRIKER REMOVAL/INSTALLATION 1. 2. 3. 4. 5. Remove the tire house trim. Remove the trunk side upper trim and trunk side lower trim. Remove the bolts. Remove the seat back striker. Install in the reverse order of removal. A6E775262361W01 A6E7752W016 End Of Sie POWER SEAT SWITCH INSPECTION 1. Disconnect the power seat switch connector. 2. Disconnect the rear tilt motor connector. 3. Inspect for continuity between the power seat switch connector terminals using an ohmmeter.
SEAT End Of Sie FRONT TILT MOTOR INSPECTION 1. Disconnect the front tilt motor connector. 2. Inspect the front tilt motor operation when B+ is applied to the terminals as shown. • If not as specified, replace the seat cushion frame. Motor operation Up Down Connection B+ A (B) B (A) GND B (A) A (B) ( ) : R.H.D. A6E7752W008 End OfTILT Sie MOTOR INSPECTION REAR 1. Disconnect the rear tilt motor connector. 2. Inspect the rear tilt motor operation when B+ is applied to the terminals as shown.
SEAT SEAT WARMER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the brake boots panel. (See S86 CONSOLE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 1 2 A6E775259000W01 Seat warmer switch (See S117 Seat Warmer Switch Removal Note.) Connector 4. Install in the reverse order of removal. A6E7752W001 Seat Warmer Switch Removal Note 1. Squeeze the tabs of seat warmer switch and pull it forward to remove it.
SEAT SEAT WARMER UNIT INSPECTION 1. Remove the front seat. (See S105 FRONT SEAT REMOVAL/INSTALLATION.) 2. Remove the seat cushion trim. 3. While inspecting for continuity between the terminals A and B of the connector, use a dryer to warm the thermostat of the seat warmer unit on seat cushion. A6E775259000W03 A6E7752W020 4. When the indication on the ohmmeter is no continuity, turn off the dryer, then use a thermometer to measure the temperature of the thermostat. 5.
BODY SHELL BODY SHELL SHROUD PANEL REMOVAL/INSTALLATION 1. 2. 3. 4. A6E775453140W01 Remove the bonnet. (See S10 BONNET REMOVAL/INSTALLATION.) Remove the front bumper. (See S47 FRONT BUMPER REMOVAL/INSTALLATION.) Remove the front combination light. (See T26 FRONT COMBINATION LIGHT REMOVAL/INSTALLATION.) Remove the front bumper reinforcement. (See S48 BUMPER REINFORCEMENT REMOVAL/ INSTALLATION.) 5. Remove in the order indicated in the table.
TROUBLESHOOTING [POWER WINDOW SYSTEM] TROUBLESHOOTING [POWER WINDOW SYSTEM] INTERMITTENT CONCERN TROUBLESHOOTING A6E778058000W01 Vibration Method • If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below. Note • There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Some of the things to check for: Connectors not fully seated. Wire harnesses not having full play.
TROUBLESHOOTING [POWER WINDOW SYSTEM] BASIC POWER WINDOW SYSTEM INSPECTION A6E778058000W03 Manual Mode Function Inspection STEP 1 INSPECTION • Turn ignition switch to ON position. • Do all windows go up and down in manual mode using power window main switch? Yes No 2 • Does each window go up and down in manual mode using power window subswitch? Yes No 3 • Turn power-cut switch UNLOCK. • Push/pull power window main switch (switches for all doors in manual mode).
TROUBLESHOOTING [POWER WINDOW SYSTEM] Automatic Window Return Function Inspection STEP 1 2 INSPECTION • Turn ignition switch to ON position. • Lower driver-side front window completely. • Use power window main switch to close driver's window in automatic mode. • Does window automatically reverse even though the glass does not encounter a foreign object while it is going up in automatic mode? • Lower driver-side front window completely.
TROUBLESHOOTING [POWER WINDOW SYSTEM] STEP 5 INSPECTION • Close all doors. • Turn ignition switch to ON position. • Push/pull power window main switch for driver-side front window after approximately 60 seconds from ignition switch OFF position. • Verify that driver-side front window does not go up or down. • Does driver-side front window go up or down? Yes No ACTION Replace power window main switch, then go to two-step down function inspection. • IG OFF timer function is normal.
TROUBLESHOOTING [POWER WINDOW SYSTEM] Diagnostic procedure STEP INSPECTION 1 INSPECT WHETHER POWER WINDOW MAIN SWITCH ENTERS FAIL-SAFE MODE OR NOT • Did driver-side front window go up or down in automatic mode? 2 VERIFY WHETHER MALFUNCTION IS IN WIRING HARNESS (BETWEEN POWER WINDOW MAIN SWITCH AND DRIVER-SIDE FRONT POWER WINDOW MOTOR) OR ELSEWHERE • Turn ignition switch ON position. • Test voltage at power window main switch connector terminal 2C (position sensor 1 signal).
TROUBLESHOOTING [POWER WINDOW SYSTEM] STEP INSPECTION 7 VERIFY WHETHER MALFUNCTION IS IN POWER WINDOW MAIN SWITCH OR ELSEWHERE • Turn ignition switch to ON position. • Test voltage at power window main switch connector terminal 2B (position sensor 2 signal). • Does voltage alternate between 0 V and approximately 12 V when driver-side front window is being gone up down? 8 VERIFY POSITION SENSOR 2 OUTPUT SIGNAL • Turn ignition switch to ON position.
TROUBLESHOOTING [POWER WINDOW SYSTEM] NO. 2 DRIVER-SIDE FRONT WINDOW DOES NOT REVERSE, EVEN WHEN ENCOUNTERING A FOREIGN OBJECT IN ITS PATH A6E778058000W06 2 POSSIBLE CAUSE Driver-side front window does not reverse, even when encountering a foreign object in its path.
TROUBLESHOOTING [POWER WINDOW SYSTEM] NO. 3 DRIVER-SIDE FRONT WINDOW REVERSES EVEN THOUGH THE GLASS DOES NOT ENCOUNTER A FOREIGN OBJECT WHILE IT IS GOING UP IN AUTOMATIC MODE A6E778058000W07 3 POSSIBLE CAUSE Driver-side front window reverses even though the glass does not encounter a foreign object while it is going up in automatic mode.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] FOREWORD A6E778269000W01 • Go to troubleshooting after identifying the specific malfunction by doing a keyless entry system preliminary inspection.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] KEYLESS ENTRY SYSTEM CHECK SHEET A6E778269000W02 • Use the sheet below as a customer interview sheet when accepting a vehicle for service. • If the symptom is Power door lock system does not operate with transmitter at all, find out how the customer uses the keyless entry system by following the check sheet below. S A6E7782W001 End Of SieENTRY SYSTEM PRELIMINARY INSPECTION KEYLESS • Perform the following preliminary inspection before troubleshooting.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP 3 INSPECTION • Did customer use keyless entry system in particular area, such as being near TV towers, power plants, power lines, or factories? Yes ACTION Attempt to lock/unlock doors with transmitter in non-interference area. If system operates: • Area of operation is bad. Explain effect of outside interference on transmitter to customer.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] TROUBLESHOOTING INDEX No. TROUBLESHOOTING ITEM 1 One or more on-board diagnostic functions inoperative. 2 All on-board diagnostic functions inoperative. 3 Transmitter ID code cannot be reprogrammed. A6E778269000W05 DESCRIPTION • Malfunction in hazard warning light system (except vehicle with theft-deterrent system), or door lock linkage system, drivers door key cylinder switch system.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION *6 CHECK TO SEE WHETHER MALFUNCTION IS IN DOOR LOCK ACTUATOR, DOOR LOCK TIMER UNIT GROUND CIRCUIT OR ELSEWHERE • Measure voltage at door lock timer unit connector terminal C, D (6 pin) during onboard diagnostic function operation. All door locked: below 1.0 V→B+→below 1.0 V (terminal D, 6 pin) All door unlocked: B+→below 1.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION *4 CHECK TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO B+ BETWEEN FUSE BLOCK AND DOOR LOCK TIMER UNIT, OR BETWEEN DOOR LOCK TIMER UNIT AND GROUND) OR ELSEWHERE • Turn ignition switch to LOCK position. • Disconnect door lock timer unit connector.
TROUBLESHOOTING [KEYLESS ENTRY SYSTEM] STEP INSPECTION 3 INSPECT TRANSMITTER BATTERY • Inspect transmitter battery.
BODY ELECTRICAL SYSTEM T LOCATION INDEX ................................................. T-5 POWER SYSTEM................................................ T-5 EXTERIOR LIGHTING SYSTEM ......................... T-6 INTERIOR LIGHTING SYSTEM .......................... T-9 WIPER AND WASHER SYSTEM ...................... T-10 WARNING AND INDICATOR SYSTEM............. T-12 THEFT-DETERRENT SYSTEM ........................ T-13 IMMOBILIZER SYSTEM ....................................
PANEL LIGHT CONTROL SWITCH INSPECTION .................................................. T-54 WIPER AND WASHER......................................... T-56 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION ............................ T-56 WINDSHIELD WIPER MOTOR DISASSEMBLY/ASSEMBLY .......................... T-56 WINDSHIELD WIPER MOTOR INSPECTION .................................................. T-56 WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION ............................
NOISE FILTER REMOVAL/INSTALLATION.......................... T-104 NOISE FILTER INSPECTION ......................... T-105 CONDENSER REMOVAL/INSTALLATION.......................... T-106 CENTER ROOF ANTENNA REMOVAL/INSTALLATION.......................... T-107 CENTER ROOF ANTENNA INSPECTION ................................................ T-107 GLASS ANTENNA INSPECTION .................... T-107 GPS ANTENNA REMOVAL/INSTALLATION.......................... T-108 ANTENNA FEEDER LOCATION .....................
DTC 35............................................................. T-183 DTC 37............................................................. T-184 INSPECTION OF DTCS FOR CONDITION DETECTION MODE........ T-185 DTC 01............................................................. T-186 DTC 05............................................................. T-186 DTC 07............................................................. T-186 DTC 11.............................................................
LOCATION INDEX LOCATION INDEX POWER SYSTEM A6E810001072W01 T A6E8110W124 .
LOCATION INDEX 8 9 10 11 12 13 14 15 Cooling fan relay No.3 (See T24 RELAY INSPECTION) Stater relay (See T24 RELAY INSPECTION) Cooling fan relay No.
LOCATION INDEX 1 2 3 4 5 6 Front combination light (See T25 DISCHARGE HEADLIGHT SERVICE WARNINGS) (See T26 FRONT COMBINATION LIGHT REMOVAL/INSTALLATION) (See T26 HEADLIGHT AIMING) Headlight bulb (See T28 HEADLIGHT BULB REMOVAL/ INSTALLATION) Discharge headlight bulb (See T25 DISCHARGE HEADLIGHT SERVICE WARNINGS) (See T28 HEADLIGHT BULB REMOVAL/ INSTALLATION) Parking light bulb (See T33 PARKING LIGHT BULB REMOVAL/ INSTALLATION) Front turn light (See T33 FRONT TURN LIGHT REMOVAL/ INSTALLATION) Fron
LOCATION INDEX 6 7 Flasher unit (See T44 FLASHER UNIT REMOVAL/ INSTALLATION) (See T44 FLASHER UNIT INSPECTION) Running light unit (See T45 RUNNING LIGHT UNIT REMOVAL/ INSTALLATION) (See T46 RUNNING LIGHT UNIT INSPECTION) A6E8112W162 .
LOCATION INDEX INTERIOR LIGHTING SYSTEM A6E810001052W02 T A6E8114W130 .
LOCATION INDEX WIPER AND WASHER SYSTEM End Of Sie A6E810001052W03 A6E8116T101 .
LOCATION INDEX 6 7 8 9 10 11 12 13 14 15 16 17 18 Rear washer motor (5HB) (See T61 REAR WASHER MOTOR REMOVAL/ INSTALLATION) (See T61 REAR WASHER MOTOR INSPECTION) Washer fluid-level sensor (5HB) (See T59 WASHER FLUID-LEVEL SENSOR REMOVAL/INSTALLATION) (See T60 WASHER FLUID-LEVEL SENSOR INSPECTION) Windshield washer hose (See T61 WINDSHIELD WASHER HOSE REMOVAL/INSTALLATION) Rear washer hose (5HB) (See T65 REAR WASHER HOSE REMOVAL/ INSTALLATION) Wiper and washer switch (See T67 WIPER AND WASH
LOCATION INDEX WARNING AND INDICATOR SYSTEM A6E810001067W01 A6E8118W012 .
LOCATION INDEX THEFT-DETERRENT SYSTEM A6E810050000W01 T A6E8120W007 .
LOCATION INDEX IMMOBILIZER SYSTEM A6E810067000W01 A6E8122W004 .
LOCATION INDEX AUDIO AND NAVIGATION SYSTEM A6E810001066W01 Audio System T A6E8124W044 .
LOCATION INDEX Car-navigation System A6E8124W045 .
LOCATION INDEX CRUISE CONTROL SYSTEM A6E810001011W01 A6E8128W017 .
LOCATION INDEX AIR BAG SYSTEM A6E810001046W01 A6E8130W049 .
POWER SYSTEM POWER SYSTEM FUSE SERVICE CAUTION A6E811066000W01 Caution • Determine and correct the cause of the burnt fuse before replacing it with the specified type. If the fuse is replaced before doing this, it may burn again. End Of Sie MAIN FUSE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the main fuse block cover. 3. Remove in the order indicated in the table. 1 2 3 A6E811066761W01 Nut Bolt (See T19 Bolt Removal Note) Main fuse 4.
POWER SYSTEM FUSE BLOCK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the left-side front side trim. (See S88 FRONT SIDE TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. 1 2 3 A6E811066730W01 Connector Bolt Fuse block 4. Install in the reverse order of removal. A6E8110W107 End Of Sie IGNITION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. (See S84 COLUMN COVER REMOVAL/INSTALLATION) 3.
POWER SYSTEM KEY REMINDER SWITCH REMOVAL/INSTALLATION 1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the column cover. Disconnect the key reminder switch connector. Remove the key reminder switch. Install in the reverse order of removal. A6E811066152W01 A6E8110W102 End Of Sie KEY REMINDER SWITCH INSPECTION 1. 2. 3. 4. Disconnect the negative battery cable. Remove the column cover. (See S84 COLUMN COVER REMOVAL/INSTALLATION) Disconnect the key reminder switch connector.
POWER SYSTEM Socket Removal Note 1. Insert a tape-wrapped screwdriver into the socket hole, then press against the ring protrusion to lift the socket toward you. A6E8110W104 2. As shown in the figure, lift out the socket until the ring protrusion locks into the lower socket hole. 3. Remove the boot panel. A6E8110W106 4. From behind the boot panel, slide a tape-wrapped screwdriver in between the socket and the ring protrusion.. 5.
POWER SYSTEM RELAY LOCATION A6E811067730W01 T A6E8110T102 . 1 2 3 4 5 6 7 8 9 Cooling fan relay No.2 Horn relay Cooling fan relay No.3 Stater relay Cooling fan relay No.4 Woofer relay Rear window defroster relay Rear fog light relay A/C relay 10 11 12 13 14 15 16 17 Main relay Headlight relay TNS relay Cooling fan relay No.
POWER SYSTEM RELAY INSPECTION A6E811067730W02 Relay Type Terminal type • • • • • • • • Four-terminal Type A • • • • • Type B Five-terminal Type C • • • • • Parts name Main relay Fuel pump relay Stater relay TNS relay Front fog light relay Rear fog light relay Horn relay Headlight cleaner relay Rear window defroster relay Woofer relay A/C relay Blower relay Cooling fan relay No.1 (except L3 engine) Cooling fan relay No.2 Cooling fan relay No.3 Cooling fan relay No.
POWER SYSTEM, EXTERIOR LIGHTING SYSTEM Type C 1. Remove the relay. 2. Inspect for continuity between the relay terminals using an ohmmeter. • If not as specified, replace the relay. A6E8110W126 A6E8110W122 End Of Sie EXTERIOR LIGHTING SYSTEM DISCHARGE HEADLIGHT SERVICE WARNINGS A6E811251060W01 Discharge headlight bulb service warnings • To prevent electrical shock when replacing the discharge headlight bulb, dry hands thoroughly, and carry out work in an area out of rain.
EXTERIOR LIGHTING SYSTEM FRONT COMBINATION LIGHT REMOVAL/INSTALLATION A6E811251060W02 Caution • Incorrect servicing of the discharge headlights could result in electrical shock. Before servicing the discharge headlights, always refer to the Discharge headlight service warnings.
EXTERIOR LIGHTING SYSTEM 6. 7. 8. 9. 10. 11. Set the headlights 3 m {10 ft} from the wall. While adjusting one headlight, mask the other. Start the engine to charge the battery. Turn on the lower-beam headlight. Set the headlight leveling switch to 0 position. Adjust the headlights by turning the adjusting screws as shown in the figure. Loosen the screws first, then tighten them.
EXTERIOR LIGHTING SYSTEM 5. 6. 7. 8. 9. Set the headlights 3 m {10 ft} from the wall. While adjusting one headlight, mask the other. Start the engine to charge the battery. Turn on the high-beam headlights. Set the headlight leveling switch to 0 position. A6E8112W157 10. Adjust the headlights by turning the adjusting screws as shown in the figure. Loosen the screws first, then tighten them.
EXTERIOR LIGHTING SYSTEM Discharge type Caution • Incorrect servicing of the discharge headlights could result in electrical shock. Before servicing the discharge headlights, always refer to the Discharge headlight service warnings. (See T25 DISCHARGE HEADLIGHT SERVICE WARNINGS) 1. Disconnect the negative battery cable. 2. Disconnect the front combination light. (See T26 FRONT COMBINATION LIGHT REMOVAL/ INSTALLATION) 3. Remove in the order indicated in the table.
EXTERIOR LIGHTING SYSTEM DISCHARGE HEADLIGHT CONTROL UNIT REMOVAL/INSTALLATION A6E811251030W03 Caution • Incorrect servicing of the discharge headlight control unit could result in electrical shock. Before servicing the discharge headlight control unit, always refer to the Discharge headlight service warnings. (See T25 DISCHARGE HEADLIGHT SERVICE WARNINGS) • When replacing the discharge headlight control unit, configuration procedure must be done before removing the auto leveling control unit.
EXTERIOR LIGHTING SYSTEM HEADLIGHT ZEROSET A6E811251030W05 Note • When the configuration is not set for the auto leveling control unit, headlight zeroset cannot be executed. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Adjust the tire air pressure to the specification. Position the unloaded vehicle on a flat, level surface. Connect the SST (WDS or equivalent) to the DLC-2. Turn the ignition switch to ON position. Turn on the headlights (low-beam). Input the vehicle information following the directions on the screen.
EXTERIOR LIGHTING SYSTEM FRONT AUTO LEVELING SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Jack up the vehicle and remove the wheel and tire. 3. Remove in the order indicated in the table. 1 2 3 4 A6E811251030W06 Connector Bolt Bracket Front auto leveling sensor 4. Install in the reverse order of removal. 5. Adjust the headlight zeroset. (See T31 HEADLIGHT ZEROSET) A6E8112W165 End Of Sie REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION 1.
EXTERIOR LIGHTING SYSTEM PARKING LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 A6E811251040W01 Cover Socket Parking light bulb 3. Install in the reverse order of removal. A6E8112W109 End Of Sie FRONT TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. A6E811251050W01 . 1 2 Socket Front turn light bulb 3. Install in the reverse order of removal.
EXTERIOR LIGHTING SYSTEM FRONT FOG LIGHT AIMING 1. 2. 3. 4. Adjust the tire air pressure to the specification. Position the unloaded vehicle on a flat, level surface. Seat one person in the drivers seat. Position the vehicle 3 m {10 ft} in front of a white screen. 5. While adjusting one fog light, mask the other. 6. Start the engine to charge the battery. 7. Turn the front fog light on. A6E811251680W01 A6E8112W157 8. Adjust the front fog light by turning the adjusting screws as shown in the figure.
EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the trunk side trim. (See S92 TRUNK SIDE TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. 1 2 3 4 5 6 A6E811251150W01 Connector Bolt Rear combination light Socket Rear turn light bulb Brake light/taillight bulb 4. Install in the reverse order of removal. A6E8112W118 End Of Sie INBOARD COMBINATION LIGHT REMOVAL/INSTALLATION A6E811251380W01 1.
EXTERIOR LIGHTING SYSTEM 2. Pleace the bracket in the proper position as shown in the figure and press it to the trunk lid (liftgate) to attach. A6E8112W121 End Of Sie HIGH-MOUNT BRAKE LIGHT REMOVAL/INSTALLATION 4SD In-vehicle-type 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 A6E811251580W01 Connector High-mount brake light Socket High-mount brake light bulb 3. Install in the reverse order of removal. A6E8112W123 Rear spoiler type 1.
EXTERIOR LIGHTING SYSTEM High-mount brake light removal note 1. Tie a string to the end of the connector of the high-mount brake light beforehand so that the connector can be passed easily through the rear spoiler during installation. A6E8112W116 5HB 1. Disconnect the negative battery cable. 2. Remove the liftgate lower trim. (See S95 LIFTGATE LOWER TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table.
EXTERIOR LIGHTING SYSTEM 6. Remove in the order indicated in the table. 1 2 3 Connector Screw Combination switch 7. Install in the reverse order of removal. A6E8112W102 End Of Sie COMBINATION SWITCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
EXTERIOR LIGHTING SYSTEM STEERING ANGLE SENSOR INSPECTION A6E811266120W03 With DSC 1. Remove the column cover. (See S84 COLUMN COVER REMOVAL/INSTALLATION) 2. Disconnect the steering angle sensor connector. 3. Connect battery positive voltage to terminal A and ground to terminal F of the steering angle sensor. 4. Turn the steering wheel to the right and left, and verify that the voltage and pulses at the terminals are as shown in the figure.
EXTERIOR LIGHTING SYSTEM LIGHT SWITCH INSPECTION Light switch LH side 1. Remove the light switch. (See T39 LIGHT SWITCH REMOVAL/INSTALLATION) 2. Inspect for continuity between the light switch terminals using an ohmmeter. • If not as specified, replace the light switch.
EXTERIOR LIGHTING SYSTEM Light switch RH side 1. Remove the light switch. (See T39 LIGHT SWITCH REMOVAL/INSTALLATION) 2. Inspect for continuity between the light switch terminals using an ohmmeter. • If not as specified, replace the light switch. Headlight switch A6E8112W131 A6E8112W146 Turn switch T A6E8112W139 A6E8112W147 End Of Sie HAZARD WARNING SWITCH INSPECTION 1. Inspection the hazard warning switch.
EXTERIOR LIGHTING SYSTEM FRONT AND REAR FOG LIGHT SWITCH INSPECTION Light switch LH side 1. Remove the light switch. (See T39 LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the light switch terminals using an ohmmeter. • If not as specified, replace the light switch. A6E811266402W01 A6E8112W140 A6E8112W148 Light switch RH side 1. Remove the light switch. (See T39 LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the light switch terminals using an ohmmeter.
EXTERIOR LIGHTING SYSTEM HEADLIGHT LEVELING SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 A6E811251030W08 Headlight leveling switch (See T43 Headlight Leveling Switch Removal Note) Connector 3. Install in the reverse order of removal. A6E8112W138 Headlight Leveling Switch Removal Note 1. Insert your hand from the lower side of the dashboard and squeeze the tabs of the headlight leveling switch. 2.
EXTERIOR LIGHTING SYSTEM BACK-UP LIGHT SWITCH INSPECTION 1. Disconnect the back-up light switch connector. 2. Inspect for continuity between the back-up light switch terminals using an ohmmeter. • If not as specified, replace the back-up light switch. A6E811217640W02 A6E8112W153 A6E8112W128 End Of Sie FLASHER UNIT REMOVAL/INSTALLATION A6E811266830W01 1. Disconnect the negative battery cable. 2. Remove the instrument cluster. (See T72 INSTRUMENT CLUSTER REMOVAL/INSTALLATION) 3.
EXTERIOR LIGHTING SYSTEM Terminal Voltage List (Reference) A6E8112W154 Terminal Signal Connected to A Power supply HAZARD 10 A fuse D Turn signal flasher (LH) Turn signal light (LH) F Flasher unit ground GND G Turn signal flasher (RH) Turn signal light (RH) H Hazard warning Hazard warning on switch I Turn switch on/ off (RH) Combination switch J Turn switch on/ off (LH) Combination switch Test condition Under any condition Voltage (V)/ Continuity B+ Turn signal light (LH) flashes
EXTERIOR LIGHTING SYSTEM RUNNING LIGHT UNIT INSPECTION A6E811266731W02 1. Connect the connector to the running light unit. 2. Connect the negative battery cable. 3. Measure the voltage at the running light unit using voltmeter. • When inspecting terminal D, H or P for continuity, disconnect the running light unit connector. 4. If the value are not as specified in the Terminal Voltage List (Reference), inspect the parts under Action and related wiring harnesses. 5.
EXTERIOR LIGHTING SYSTEM Terminal H Signal Connected to Front fog light Front and rear on/off fog light switch I TNS on/off K Headlight relay on/off M Flash-to-pass Headlight switch on/off (dimmer switch) O P Headlight high operation Headlight (high-beam) on/off Headlight switch Headlight relay Headlight switch (dimmer switch: HI position) Headlight switch Test condition Front and rear fog light switch at OFF position: inspect for continuity to ground Front and rear fog light switch at ON
INTERIOR LIGHTING SYSTEM INTERIOR LIGHTING SYSTEM FRONT MAP LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 A6E811451310W01 Front map light (See T48 Front Map Light Removal Note) Connector Socket Map light bulb 3. Install in the reverse order of removal. A6E8114W102 Front Map Light Removal Note 1. Insert a tape-wrapped flathead screwdriver into the gap between the headliner and the front map light. 2.
INTERIOR LIGHTING SYSTEM REAR MAP LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 A6E811451311W01 Rear map light (See T49 Rear Map Light Removal Note) Connector Socket Rear map light bulb 3. Install in the reverse order of removal. A6E8114W104 Rear Map Light Removal Note 1. Insert a tape-wrapped flathead screwdriver into the gap between the headliner and the rear map light. 2. Push the hooks to remove the rear map light.
INTERIOR LIGHTING SYSTEM CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 A6E811451441W01 Cargo compartment light Connector Lens Cargo compartment light bulb 3. Install in the reverse order of removal. A6E8114W101 End Of Sie CARGO COMPARTMENT LIGHT INSPECTION 1. Remove the cargo compartment light. (See T50 CARGO COMPARTMENT LIGHT REMOVAL/ INSTALLATION) 2.
INTERIOR LIGHTING SYSTEM TRUNK COMPARTMENT LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 A6E811451440W01 Lens Trunk compartment light bulb 3. Install in the reverse order of removal. A6E8114W112 End Of Sie TRUNK COMPARTMENT LIGHT SWITCH INSPECTION 1. Remove the trunk lid trim. (See S93 TRUNK LID TRIM REMOVAL/INSTALLATION) 2. Disconnect the trunk compartment light switch connector. 3.
INTERIOR LIGHTING SYSTEM DOOR SWITCH REMOVAL/INSTALLATION Front 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 A6E811466540W01 Screw Door switch Connector 3. Install in the reverse order of removal. A6E8114W108 Rear 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 Screw Door switch Connector 3. Install in the reverse order of removal. A6E8114W109 End Of Sie DOOR SWITCH INSPECTION 1.
INTERIOR LIGHTING SYSTEM IGNITION KEY ILLUMINATION BULB REMOVAL/INSTALLATION End Of Sie 1. 2. 3. 4. Disconnect the negative battery cable. Remove the column cover. (See S84 COLUMN COVER REMOVAL/INSTALLATION) Remove the ignition key illumination bulb. Install in the reverse order of removal. A6E811460231W01 A6E8114W129 End Of Sie GLOVE COMPARTMENT LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table.
INTERIOR LIGHTING SYSTEM PANEL LIGHT CONTROL SWITCH INSPECTION A6E811466600W02 1. Connect the connector to the panel light control switch. 2. Connect the negative battery cable. 3. Measure the voltage at the panel light control switch using voltmeter. • When inspecting terminal B for continuity, disconnect the panel light control switch connector. 4. If the value are not as specified in the Terminal Voltage List (Reference), inspect the parts under Action and related wiring harnesses. 5.
INTERIOR LIGHTING SYSTEM Terminal C inspection 1. Measure the wave pattern of the terminal C on the panel light control switch using an oscilloscope. 2. Set the headlight switch to either the TNS or headlight position. 3. Set the panel light control switch to the brightest position. A6E8114W124 4. Verify that the pattern on the screen is as shown in the figure. A6E8114W125 5.
WIPER AND WASHER WIPER AND WASHER WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION A6E811667340W01 1. Disconnect the negative battery cable. 2. Remove the windshield wiper arm and blade. (See T57 WINDSHIELD WIPER ARM AND BLADE REMOVAL/ INSTALLATION.) 3. Remove the cowl grille. (See S50 COWL GRILLE REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 1 2 3 Connector Bolt Windshield wiper motor 5. Install in the reverse order of removal. 6. Adjust the windshield wiper arm and blade.
WIPER AND WASHER R.H.D. 1. Disconnect the windshield wiper motor connector. 2. Connect battery positive voltage to terminal B or A and ground to terminal D, and inspect the operation of the windshield wiper motor as indicated below. Terminal B A Operation High Low 3. Disconnect battery positive voltage from terminal B of the motor while the wipers are operating. 4. Verify that the wipers do not stop in the park position. 5.
WIPER AND WASHER WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT 1. Operate the windshield wiper motor to set the wipers in the park position. 2. Set the windshield wiper arms height as shown. A6E811667320W02 A6E8116W107 End Of Sie WASHER TANK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 5 6 A6E811667481W01 Bolt Connector Washer hose Clip Headlight cleaner hose Washer tank 3. Install in the reverse order of removal.
WIPER AND WASHER WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T58 WASHER TANK REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. 1 2 A6E811676670W01 Windshield washer motor Grommet 4. Install in the reverse order of removal. A6E8116W123 End Of Sie WINDSHIELD WASHER MOTOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T58 WASHER TANK REMOVAL/INSTALLATION) 3.
WIPER AND WASHER WASHER FLUID-LEVEL SENSOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T58 WASHER TANK REMOVAL/INSTALLATION) 3. Insoect for continuity between the washer fluidlevel sensor terminals using an ohmmeter. 4. Verify that the windshield washer motor operates. • If not as specified, replace the washer fluidlevel sensor. A6E811676670W04 A6E8116W130 A6E8116W144 End Of Sie WINDSHIELD WASHER NOZZLE REMOVAL/INSTALLATION 1. 2. 3. 4.
WIPER AND WASHER WINDSHIELD WASHER HOSE REMOVAL/INSTALLATION 1. Remove the bonnet insulator. 2. Partially peel off the right side mud guard. 3. Remove in the order indicated in the table. 1 2 3 A6E811650601W01 Clip Joint pipe Windshield washer hose 4. Install in the reverse order of removal. A6E8116W126 End Of Sie REAR WASHER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the washer tank. (See T58 WASHER TANK REMOVAL/INSTALLATION) 3.
WIPER AND WASHER REAR WIPER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the rear wiper arm and blade. (See T63 REAR WIPER ARM AND BLADE REMOVAL/ INSTALLATION.) 3. Remove the liftgate lower trim. (See S95 LIFTGATE LOWER TRIM REMOVAL/INSTALLATION) 4. Remove in the order indicated in the table. 1 2 3 4 A6E811667450W01 Connector Outer bushing Bolt Rear wiper motor 5. Install in the reverse order of removal. 6. Adjust the rear wiper arm and blade.
WIPER AND WASHER 7. Verify that the rear wiper stops in the park position. • If not as specified, replace the rear wiper motor. A6E8116W119 A6E8116W133 End Of Sie REAR WIPER ARM AND BLADE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 1 2 3 4 5 A6E811667420W01 Cap Nut Rear wiper arm (See T63 Rear Wiper Arm Installation Note) Rear wiper blade Rubber brush 2. Install in the reverse order of removal. 3. Adjust the rear wiper arm and blade.
WIPER AND WASHER REAR WIPER ARM AND BLADE ADJUSTMENT 1. Operate the rear wiper motor to set the wiper in the park position. 2. Set the rear wiper arm onto the ceramics end line. A6E811667420W02 A6E8116W109 End Of Sie REAR WASHER NOZZLE REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. Disconnect the negative battery cable. Remove the liftgate upper trim. (See S94 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION) Remove the rear washer hose from the rear washer nozzle. Compress the tabs of the rear washer nozzle.
WIPER AND WASHER REAR WASHER HOSE REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. Disconnect the negative battery cable. Remove the washer tank. (See T58 WASHER TANK REMOVAL/INSTALLATION) Partially peel off the right side mud guard. Remove rear washer hose No.1 from the clips. Remove rear washer hose No.1 and joint pipe A. Remove the A-pillar trim. (See S87 A-PILLAR TRIM REMOVAL) A6E811667470W01 A6E8116W148 7. 8. 9. 10. Remove rear washer hose No.2 from clip A. Remove clips B from the body.
WIPER AND WASHER INTERMITTENT REAR WIPER RELAY REMOVAL/INSTALLATION 5HB 1. Disconnect the negative battery cable. 2. Remove the trunk side trim. (See S92 TRUNK SIDE TRIM REMOVAL/INSTALLATION) 3. Remove in the order indicated in the table. 1 2 3 A6E811666810W01 Connector Bolt Interittent rear wiper relay 4. Install in the reverse order of removal. A6E8116W101 End Of Sie INTERMITTENT REAR WIPER RELAY INSPECTION A6E811666810W02 1. Connect the connector to the intermittent rear wiper relay. 2.
WIPER AND WASHER Terminal G I Signal Rear wiper switch INT IG 2 Connected to Test condition Rear wiper switch at INT position Ignition switch at • Rear wiper Rear wiper switch switch at ON position OFF position • Rear wiper switch at ON position Ignition switch at ON position R. WIP 10 A fuse Other Voltage (V)/ Continuity 0 B+ B+ 0 Action • Inspect R. WIP 10 A fuse • Inspect wiper and washer switch (See T 68 WIPER AND WASHER SWITCH INSPECTION) • Inspect related harness • Inspect R.
WIPER AND WASHER WIPER AND WASHER SWITCH INSPECTION Windshield Wiper And Washer Switch Without vehicle-speed sensing type wipers 1. Remove the wiper and washer switch. (See T67 WIPER AND WASHER SWITCH REMOVAL/ INSTALLATION) 2. Inspect for continuity between the wiper and washer switch terminals using an ohmmeter. • If not as specified, replace the wiper and washer switch. A6E811666122W02 A6E8116W146 A6E8116W135 With vehicle-speed sensing type wipers 1. Remove the wiper and washer switch.
WIPER AND WASHER 4. Inspect whether the vehicle speed signal to the wiper and washer switch terminal N (D) is input correctly using an oscilloscope. • Connect the oscilloscope probes to the wiper and washer switch terminal N (D) (+) and terminal M (C) (-). • Set oscilloscope to 1V/DIV (Y), 5ms/DIV (X). • Verify that the wave pattern below is displayed while the vehicle is moving at 30 km/h {19 mph}. Note • As the vehicle speed increases, the frequency shortens. 5.
WIPER AND WASHER HEADLIGHT CLEANER MOTOR INSPECTION 1. 2. 3. 4. Disconnect the negative battery cable. Remove the washer tank. (See T58 WASHER TANK REMOVAL/INSTALLATION) Connect battery positive voltage to terminal D and ground to terminal C of the motor. Verify that the headlight cleaner motor operates. • If the motor does not operate, replace the headlight cleaner motor. A6E811651030W02 A6E8116W137 End Of Sie HEADLIGHT CLEANER NOZZLE REMOVAL/INSTALLATION 1. Remove the front bumper.
WIPER AND WASHER HEADLIGHT CLEANER HOSE REMOVAL/INSTALLATION 1. Remove the front bumper. (See S47 FRONT BUMPER REMOVAL/INSTALLATION) 2. Remove in the order indicated in the table. 1 2 3 A6E811651030W06 Clip Headlight cleaner hose Check valve 3. Install in the reverse order of removal. A6E8116W118 End Of Sie HEADLIGHT CLEANER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table.
WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER REMOVAL/INSTALLATION A6E811855430W01 Caution • When replacing the instrument cluster, the configuration procedure must be performed before removing the instrument cluster. If the configuration procedure is not performed before removing the instrument cluster, it is possible that the instrument cluster will not operate normally. 1. Configurate the instrument cluter (when only replacing it).
WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY A6E811855430W03 Caution • If the instrument cluster is dropped or the print plate is damaged, the system will not work properly and it may be the cause of trouble or malfunctions. 1. Disassemble in the order indicated in the table. 1 2 3 Lens Case Meter unit 2. Assemble in the reverse order of disassembly. A6E8118W004 End Of Sie INSTRUMENT CLUSTER INSPECTION Speedometer Using the input/output check mode 1.
WARNING AND INDICATOR SYSTEM Tachometer Using the input/output check mode 1. Inspect the tachometer by setting it in the input/output check mode DTC 13. Using the SSTs (WDS or equivalent) Caution • If the engine speed exceeds the allowable range, the engine could be damaged. Therefore, when inspecting the tachometer, do not allow the engine speed to exceed the allowable range indication on the tachometer. 1. Connect the SSTs (WDS or equivalent) to the vehicle DLC-2 16-pin connector. 2.
WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE A6E811855430W06 Note • In this mode, it is possible to check the items in the following chart.
WARNING AND INDICATOR SYSTEM Operating Order A6E8118W009 T76
WARNING AND INDICATOR SYSTEM Checking Order Note • When inspecting more than two DTCs, perform the inspection by following the priority order of inspection indicated in the chart below. Priority order of inspection 1 2 3 IG switch position ON LOCK Check code 22 01, 04, 08, 12, 13, 14, 16, 18, 23, 25, 26 31 Inspection of Diagnostic Trouble Codes DTC 01 Buckle switch on/off signal Diagnostic procedure STEP 1 INSPECTION Unfasten driver-side seat belt. (Buckle switch on.
WARNING AND INDICATOR SYSTEM DTC 04 Door switch on/off signal Diagnostic procedure STEP 1 2 3 4 INSPECTION Open driver-side door. (Door switch on.) Open passenger-side door. (Door switch on.) Open rear door on drivers side. (Door switch on.) Open rear door on passengers side. (Door switch on.) INDICATION ACTION Close driver-side door, then go to next step. Measure voltage at instrument cluster terminal 1J. Is voltage 0 V? • If as specified, replace instrument cluster.
WARNING AND INDICATOR SYSTEM STEP 5 INSPECTION Close all doors. (Door switch off.) INDICATION ACTION Measure voltage at instrument cluster terminals 1I and 1J. Is voltage B+? • If as specified, replace instrument cluster. • If not as specified, inspect following parts. Door switch Wiring harness (Instrument clusterdoor switch) Input signals to instrument cluster are okay. DTC 08 TNS relay on/off signal Diagnostic procedure STEP 1 INSPECTION Turn headlight switch to TNS position. (TNS relay on.
WARNING AND INDICATOR SYSTEM DTC 13 Operation signal to tachometer INSPECTION Wait for 2 seconds after selecting DTC 13. INDICATION SITUATION ACTION Tachometer needle moves Tachometer is okay. full scale then returns to 3000 rpm. Other than stated above. Replace instrument cluster. DTC 14 Operation signal to buzzer INSPECTION Wait for 2 seconds after selecting DTC 14. INDICATION DTC 16 Operation signal to fuel-level warning light INSPECTION INDICATION Wait for 2 seconds after selecting DTC 16.
WARNING AND INDICATOR SYSTEM DTC 22 Fuel level signal Diagnostic procedure STEP 1 INSPECTION Select DTC 22 with fuel gauge sender unit connector disconnected. INDICATION Other than stated above. 2 Connect between instrument cluster terminals 2D and 2M. Using SST (Fuel and thermometer checker) or resistor, input 20 ohms to between instrument cluster terminals 2D and 2M. Using SST (Fuel and thermometer checker) or resistor, input 60 ohms to between instrument cluster terminals 2D and 2M.
WARNING AND INDICATOR SYSTEM DTC 23 Operation signal to fuel gauge INSPECTION Wait for 2 seconds after selecting DTC 23. INDICATION SITUATION Fuel gauge indicates in following order for every 2 seconds. • F→1/2→E→F (fixed) Other than stated above. ACTION Fuel gauge is okay. Replace instrument cluster. Replace instrument cluster. DTC 25 Operation signal to water temperature gauge INSPECTION INDICATION Wait for 2 seconds after selecting DTC 25. DTC 26 LCD indication INSPECTION Select DTC 26.
WARNING AND INDICATOR SYSTEM STEP 2 INSPECTION Remove key from steering lock (Key reminder switch off.) INDICATION ACTION Measure voltage at instrument cluster terminal 2B. Is voltage 0 V? • If as specified, replace instrument cluster. • If not as specified, inspect following parts. Key reminder switch Wiring harness (Key reminder switch instrument cluster) Input signal to instrument cluster is okay. End Of Sie PID/DATA MONITOR AND RECORD PROCEDURE A6E811855430W07 1.
WARNING AND INDICATOR SYSTEM OIL PRESSURE SWITCH INSPECTION A6E811818500W01 1. Verify that the oil pressure warning light illuminates when the ignition switch is at ON position. 2. Verify that the oil pressure warning light goes off when the engine is started. • If the oil pressure warning light does not illuminate or remains illuminated, inspect the related wiring harness. If the related wiring harness are normal, inspect the oil pressure. (See D3 OIL PRESSURE INSPECTION.
THEFT-DETERRENT SYSTEM THEFT-DETERRENT SYSTEM BONNET SWITCH INSPECTION A6E812001084W01 Note • Bonnet switch has a built-in bonnet lock. 1. 2. 3. 4. 5. Open the bonnet. Disconnect the negative battery cable. Remove the radiator grille. Disconnect the bonnet switch connector. Check the continuity between the bonnet switch terminals A and B using an ohmmeter. • If there is continuity, replace the bonnet switch. T A6E8120W002 6. Lock the bonnet lock using a flat-head screwdriver or equivalent as shown.
THEFT-DETERRENT SYSTEM THEFT-DETERRENT CONTROL MODULE REMOVAL/INSTALLATION A6E812067790W01 1. Disconnect the negative battery cable. 2. Remove the center panel module. (See T96 CENTER PANEL MODULE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 1 2 3 Screw Connector Theft-deterrent control module 4. Install in the reverse order of removal. A6E8120W001 End Of Sie THEFT-DETERRENT CONTROL MODULE INSPECTION A6E812067790W02 1.
THEFT-DETERRENT SYSTEM Terminal I J Signal Theft-deterrent siren on/off • Theft-deterrent system recognition signal output • Keyless entry system operation signal input Connected to Theft-deterrent siren Horn on/off Horn relay L Theft-deterrent control module ground GND N O P Q R S Key reminder switch on/off Intruder sensor on/off Bonnet open/closed Trunk compartment light switch/cargo compartment light switch on/off Door open/closed Theft-deterrent system alarm: Active Theft-deterr
THEFT-DETERRENT SYSTEM Terminal T Signal Lock/unlock U V W Lock/unlock Engine speed X Connected to • Passengers door lock-link switch • Rear door lock-link switch • Drivers door lock-link switch Test condition Voltage (V)/ continuity Passengers and rear door lock-link switch locked: inspect for continuity to ground No Passengers or any rear door lock-link switch unlocked: inspect for continuity to ground Yes Drivers door lock-link switch locked: inspect for continuity to g
THEFT-DETERRENT SYSTEM INTRUDER SENSOR REMOVAL/INSTALLATION 1. 2. 3. 4. A6E812000172W01 Disconnect the negative battery cable. Remove the headliner. Remove in the order indicated in the table. Install in the reverse order of removal. A6E8120W005 . 1 2 Connector Screw 3 Intruder sensor End Of Sie THEFT-DETERRENT SIREN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the left side trunk side trim. 3. Remove in the order indicated in the table.
IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM COIL REMOVAL/INSTALLATION A6E812267004W01 Note • Do not remove the coil unless you are replacing it. • When only the coil is replaced, the immobilizer system reprogram procedure is not necessary. 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Remove in the order indicated in the table. 1 2 Connector Coil 4. Install in the reverse order of removal.
IMMOBILIZER SYSTEM 1. Cut new transponder-equipped key(s). 2. Using key 1, turn ignition switch to ON position. (1) Observe illumination of security light in instrument cluster. (2) After the security light turns off, turn key 1 to LOCK position within 2 seconds and remove it from the steering lock. 3. Repeat Step 2 with key 2. 4. Repeat Step 2 with key 3. 5. If there are 48 keys (valid and/or new keys), repeat Step 2. When the customer has only one or no valid key A6E8122W002 1.
IMMOBILIZER SYSTEM Enabling/Disabling Key Reprograming Without Using SST (WDS or Equivalent) Note • With this function, the need for use of the SST (WDS or equivalent) to perform key registration when following the "When the customer has two or more valid keys" procedure can be optionally inhibited or prohibited. This function is provided to prohibit drivers from performing the reprogram procedure on vehicles owned by rental car companies or other large vehicle fleet owners. 1. 2. 3. 4.
AUDIO AND NAVIGATION SYSTEM AUDIO AND NAVIGATION SYSTEM ANTI-THEFT SYSTEM A6E812466900W01 Alarm Conditions • If the anti-theft system protection has been activated, any one of the following conditions will trigger the system: Disconnected battery cable Discharged battery Disconnected audio unit connectors • If the system is triggered, the audio unit will then be inoperative when it is reconnected to a power source, and code will flash on the display until the preselected code number is input.
AUDIO AND NAVIGATION SYSTEM 6. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds. CODE will be displayed for approximately 5 seconds. After it disappears, the code number is set. 7. If Err (error) appears on the display, repeat the procedure from Step 1. If input error is repeated three times, turn the ignition switch to LOCK position and repeat the procedure from Step 1.
AUDIO AND NAVIGATION SYSTEM 5. With the code number displayed, press the AUTO-M button, then simultaneously press channel button 6 for approximately 2 seconds. CODE will be displayed for approximately 5 seconds. After it disappears, the code number is canceled. 6. If Err (error) appears on the display, repeat the procedure from Step 4. A6E8124W025 Canceling Anti-theft Operation Properly input the selected code number to deactivate the anti-theft system and resume normal audio operation. 1.
AUDIO AND NAVIGATION SYSTEM CENTER PANEL MODULE REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 1 2 3 4 5 6 7 Cancel the anti-theft operation. (with anti-theft system) (See T93 ANTI-THEFT SYSTEM.) Disconnect the negative battery cable. Remove the glove compartment. Remove the rear console. Remove in the order indicated in the table. A6E812466900W02 Dial (manual A/C only) Screw (manual A/C only) Screw Bolt Center panel module (See T96 Center Panel Module Removal Note) Connector Antenna feeder 6.
AUDIO AND NAVIGATION SYSTEM CENTER PANEL MODULE DISASSEMBLY/ASSEMBLY A6E812466900W03 Caution • Before disassembling the center panel module, spread a cloth on the floor to put the disassembled parts on. This protects the surface of the panel from scratches or dirt. 1. Remove the center panel module. (See T96 CENTER PANEL MODULE REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table.
AUDIO AND NAVIGATION SYSTEM CAR-NAVIGATION UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove in the order indicated in the table. 1 2 3 A6E812466902W01 Bolt Car-navigation unit (See T98 Car-navigation Unit Installation Note) Connector 4. Install in the reverse order of removal. A6E8124W015 Car-navigation Unit Installation Note 1.
AUDIO AND NAVIGATION SYSTEM 2. While pressing down the unit behind the LCD unit, pull the LCD unit out from the dashboard. A6E8124W018 End Of Sie AUDIO CONTROL SWITCH REMOVAL/INSTALLATION A6E812400148W01 Note • The audio control switch and the cruise control switch use a common connector. 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (See T120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) 3. Remove the steering wheel. 4.
AUDIO AND NAVIGATION SYSTEM AUDIO CONTROL SWITCH INSPECTION A6E812400148W02 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (See T120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) 3. Disconnect the audio control switch connector. 4. Measure the resistance and inspect for continuity between the cruise control switch terminals using an ohmmeter. • If not as specified, replace the cruise control switch.
AUDIO AND NAVIGATION SYSTEM FRONT DOOR SPEAKER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front door trim. 3. Remove in the order indicated in the table. 1 2 3 A6E812466960W01 Screw Connector Front door speaker (See T101 Front Door Speaker Installation Note) 4. Install in the reverse order of removal. A6E8124W001 Front Door Speaker Installation Note 1. Attach the speaker with the wiring harness placed in the groove of the door unit panel.
AUDIO AND NAVIGATION SYSTEM REAR DOOR SPEAKER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the rear door trim. 3. Remove in the order indicated in the table. 1 2 3 A6E812466964W01 Screw Connector Rear door speaker (See T102 Rear Door Speaker Installation Note) 4. Install in the reverse order of removal. A6E8124W003 Rear Door Speaker Installation Note 1. Attach the speaker with the wiring harness placed in the groove of the door unit panel.
AUDIO AND NAVIGATION SYSTEM TWEETER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 5 A6E812468966W01 Inner garnish Connector Screw Cover Tweeter 3. Install in the reverse order of removal. A6E8124W004 End Of Sie TWEETER INSPECTION 1. Inspect for resistance between the tweeter terminals using an ohmmeter. • If not as specified, replace the tweeter. A6E812468966W02 A6E8124W033 2.
AUDIO AND NAVIGATION SYSTEM 5HB 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 Temporary spare tire cover Wing bolt Connector Woofer 3. Install in the reverse order of removal. A6E8124W006 End Of Sie WOOFER INSPECTION 1. Inspect for continuity between the audio amplifier connector terminals and woofer connector terminals using an ohmmeter. • If not as specified, replace the related wiring harnesses. A6E812466967W02 A6E8124W024 2.
AUDIO AND NAVIGATION SYSTEM Rear Window Defroster Noise Filter 1. Disconnect the negative battery cable. 2. Remove the rear package trim. 3. Remove in the order indicated in the table. 1 2 3 Bolt Connector Noise filter 4. Install in the reverse order of removal. A6E8124W009 End Of Sie NOISE FILTER INSPECTION Brake Light Noise Filter 1. Inspect for resistance and continuity between the noise filter terminals using an ohmmeter. • If not as specified, replace the noise filter.
AUDIO AND NAVIGATION SYSTEM Rear Window Defroster Noise Filter 1. Inspect for resistance and continuity between the noise filter terminals using an ohmmeter. • If not as specified, replace the noise filter. A6E8124W037 A6E8124W036 End Of Sie CONDENSER REMOVAL/INSTALLATION 4SD 1. Disconnect the negative battery cable. 2. Remove the rear package trim. 3. Remove in the order indicated in the table. 1 2 3 A6E812466869W03 Bolt Connector Condenser 4. Install in the reverse order of removal.
AUDIO AND NAVIGATION SYSTEM CENTER ROOF ANTENNA REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the headliner. (See S96 HEADLINER REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 1 2 3 4 A6E812466939W01 Antenna rod Antenna feeder Nut Center roof antenna 4. Install in the reverse order of removal. 5. After installation, verify that the rubber of the center roof antenna is installed to the roof panel with no space between them.
AUDIO AND NAVIGATION SYSTEM GPS ANTENNA REMOVAL/INSTALLATION A6E812466936W01 1. Disconnect the negative battery cable. 2. Remove the instrument cluster. 3. Remove in the order indicated in the table. 1 2 Connector GPS antenna 4. Install in the reverse order of removal. A6E8124W022 End Of Sie ANTENNA FEEDER LOCATION A6E812466941W01 A6E8124W038 . 1 2 3 Front antenna feeder Rear antenna feeder No.1 Rear antenna feeder No.
AUDIO AND NAVIGATION SYSTEM FRONT ANTENNA FEEDER INSPECTION 1. Verify that there is no continuity between the front antenna feeder terminals A and B using an ohmmeter. 2. Inspect for continuity between the front antenna feeder terminals using an ohmmeter. • If not as specified, replace the instrument panel harness. A6E812466941W02 A6E8124W039 A6E8124W047 End Of Sie REAR ANTENNA FEEDER INSPECTION 1. Verify that there is no continuity between antenna feeder terminals A and B using an ohmmeter.
CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CRUISE ACTUATOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 3 4 5 6 7 A6E812866310W01 Cover (See T110 Cover Removal Note) Nut Connector Actuator cable (See T112 ACTUATOR CABLE REMOVAL) (See T114 ACTUATOR CABLE INSTALLATION) Screw Bracket Cruise actuator 3. Install in the reverse order of removal. A6E8128W001 Cover Removal Note 1.
CRUISE CONTROL SYSTEM Terminal Voltage Table (Reference) A6E8128W013 Terminal A Signal Vehicle speed B C Brake switch on/off D E O/D control (ATX only) MTX F ATX Connected to • DSC HU/CM (with DSC) • ABS (ABS/ TCS) HU/CM (with ABS (ABS/TCS)) Brake switch 1. Ignition switch at ON position and cruise control main switch held at on. 2. Front tire rotating PCM TR switch Voltage (V) /Continuity Alternates below 1.0 and 5 Depress brake pedal B+ Replace brake pedal Below 1.
CRUISE CONTROL SYSTEM Terminal J K L Signal Cruise control switch position Connected to Cruise control switch Brake switch on/off Brake switch 2 IG1 METER IG 15 A fuse Test condition Inspect for resistance Ignition switch at ON position Cruise control main switch held at on SET/COAST switch held at on RESUME/ ACCEL switch held at on CANCEL switch held at on Depress brake pedal Other Ignition switch at ON position Ignition switch at LOCK position or ACC position Voltage (V) /Continuity Acti
CRUISE CONTROL SYSTEM 6. Remove the actuator cable from the bracket A6E8128W004 7. Remove the end fitting of the actuator cable from the cruise actuator. T A6E8128W005 8. Squeeze the hooks of the grommet, and remove it from the cruise actuator. 9. Remove the actuator cable.
CRUISE CONTROL SYSTEM ACTUATOR CABLE INSTALLATION 1. Slide the lock lever in the direction shown by the arrow to unlock the adjuster. A6E812866311W02 A6E8128W009 2. Turn the ratchet ring to release lock in the direction shown by the arrow. A6E8128W010 3. Install the actuator cable to the cruise actuator. Caution • Due to the possibility of actuator cable damage, make sure there is no twisting in the cable when installing. 4. Install the cruise actuator. (See T110 CRUISE ACTUATOR REMOVAL/INSTALLATION.
CRUISE CONTROL SYSTEM 7. Install the grommet to the cable bracket. 8. Move the throttle, and install the end fitting of the actuator cable to the throttle. Caution • Due to the possibility of actuator cable damage, make sure there is no twisting in the cable when installing. A6E8128W011 9. To adjust the free play, push or pull the actuator cable directly behind the spring two times. A6E8128W014 T 10. Turn the ratchet ring in the direction shown by the arrow to lock it. A6E8128W015 11.
CRUISE CONTROL SYSTEM End Of Sie CRUISE CONTROL SWITCH INSPECTION A6E812866341W02 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (See T120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) 3. Disconnect the cruise control switch connector. 4. Inspect for resistance and continuity between the cruise control switch terminals using an ohmmeter. • If not as specified, replace the cruise control switch.
AIR BAG SYSTEM AIR BAG SYSTEM SERVICE WARNINGS Component Disassembly • Disassembling and reassembling the components of the air bag system can render the system inoperative, which may result in serious injury or death in the event of an accident. Do not disassemble any air bag system components. A6E813001046W01 A6E8130W044 Wiring Harness Repair • Incorrectly repairing an air bag system wiring harness can accidentally deploy the air bag module or pre-tensioner seat belt, which can cause serious injury.
AIR BAG SYSTEM Air Bag Module Handling • A live (undeployed) air bag module may accidentally deploy when it is handled and cause serious injury. When carrying a live (undeployed) air bag module, point the front surface away from your body to lessen the chance of injury in case it deploys. A6E8130W022 • A live (undeployed) air bag module placed face down on a surface is dangerous. If the air bag module deploys, the motion of the module can cause serious injury.
AIR BAG SYSTEM Side Air Bag Sensor Handling • Disconnecting the side air bag sensor connector or removing the side air bag sensor with the ignition switch at ON position can cause the side air bag sensor to operate and the side air bag module to deploy, which may seriously injure you.
AIR BAG SYSTEM DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION A6E813057010W01 Warning • Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag module. (See T117 SERVICE WARNINGS.) • Due to the adoption of 2-step deployment control in both the driver-side air bag module, depending on the impact force, it is possible that inflator No. 2 might not deploy.
AIR BAG SYSTEM PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION A6E813057050W01 Warning • Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag module. (See T117 SERVICE WARNINGS.) • Due to the adoption of 2-step deployment control in both the passenger-side air bag module, depending on the impact force, it is possible that inflator No. 2 might not deploy.
AIR BAG SYSTEM 1. Remove in the order indicated in the table. 1 2 3 4 Cover Bolt Connector (See T122 Connector Removal Note) Side air bag module 2. Install in the reverse order of removal. 3. Turn the ignition switch to ON position. 4. Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off. • If the air bag system warning light does not operate in the manner described above, there are malfunctions in the system.
AIR BAG SYSTEM Connector Removal Note 1. Using a flathead screwdriver, pry out the connector's stopper plate. 2. Disconnect the connector. A6E8130W002 Curtain Air Bag Module Installation Note (4SD Right Side) 1. Pass the curtain air bag module harness through the hole in the body.
AIR BAG SYSTEM 4. Remove in the order indicated in the table. 1 2 3 Bolt Connector Side air bag sensor 5. Install in the reverse order of removal. 6. Turn the ignition switch to ON position. 7. Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off. • If the air bag system warning light does not operate in the manner described above, there are malfunctions in the system. Inspect the system using the on-board diagnostic function.
AIR BAG SYSTEM CLOCK SPRING REMOVAL/INSTALLATION A6E813066123W01 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (See T120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) 3. Remove the steering wheel. (See N7 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 4. Remove the column cover. 5. Remove in the order indicated in the table. 1 2 3 Screw Connector Clock spring (See T125 Clock Spring Installation Note) 6. Install in the reverse order of removal. 7.
AIR BAG SYSTEM 4. Align the mark on the clock spring with the mark on the outer housing. A6E8130W048 End Of Sie CLOCK SPRING INSPECTION 1. Remove the clock spring. 2. Inspect for continuity between the clock spring terminals using an ohmmeter. • If not as specified, replace the clock spring. A6E813066123W03 A6E8130W009 A6E8130W010 Note • When the vehicle-side connector of clock spring is disconnected, the terminals 1A,1B, 1C and 1D are shorted to prevent unexpected deployment of the air bag module.
AIR BAG SYSTEM End Of Sie PASSENGER-SIDE AIR BAG CUT-OFF INDICATOR LIGHT REMOVAL/INSTALLATION A6E813001046W02 1. Remove the center panel module. (See T96 CENTER PANEL MODULE REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 1 2 Socket Passenger-side air bag cut-off indicator light bulb 3. Install in the reverse order of removal.
AIR BAG SYSTEM 2. Connect the SST (Adapter harness) to the driverside air bag module as shown in the figure. 3. Install the driver-side air bag module. (See T120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) A6E8130W011 4. Connect the SST (Deployment tool) to the SST (Adapter harness). 5. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal. 6. Verify that the red light on the SST (Deployment tool) is illuminated. 7.
AIR BAG SYSTEM 4. Connect the SST (Deployment tool) to the SST (Adapter harness). 5. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal. 6. Verify that the red light on the SST (Deployment tool) is illuminated. 7. Make sure all persons are standing at least 6 m {20 ft} away from the vehicle. A6E8130W050 8. Press the activation switch on the SST (Deployment tool) to deploy the passenger-side air bag module. 9.
AIR BAG SYSTEM 7. Press the activation switch on the SST (Deployment tool) to deploy the side air bag module. A6E8130W028 Curtain air bag module 1. Remove the side tire house trim. (4SD) 2. Remove the side trunk side trim. (5HB) 3. Disconnect the curtain air bag module connector. 4. Connect the SST (Adapter harness) to the curtain air bag module. A6E8130W012 5. Connect the SST (Deployment tool) to the SST (Adapter harness). 6.
AIR BAG SYSTEM 9. Press the activation switch on the SST (Deployment tool) to deploy the curtain air bag module. A6E8130W028 Pre-tensioner seat belt 1. Remove the B-pillar lower trim. 2. Remove the pre-tensioner seat belt and connect the SST (Adapter harness) to it as shown in the figure. (See S100 FRONT SEAT BELT REMOVAL/INSTALLATION.) 3. Install the pre-tensioner seat belt. A6E8130W030 4. Connect the SST (Deployment tool) to the SST (Adapter harness). 5.
AIR BAG SYSTEM Driver-side air bag module Warning • Driver-side air bag module is the dual inflator type. When the inflators are forced to be deployed simultaneously, one of them may fail to deploy. When disposing the air bag module, the inflators may be deployed accidentally. Make sure to deploy the inflators sequentially, following the procedures below. 1. Remove the driver-side air bag module. (See T120 DRIVER-SIDE AIR BAG MODULE REMOVAL/ INSTALLATION.) 2.
AIR BAG SYSTEM 6. Connect the SST (Deployment tool) to the SST (Adapter harness). 7. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal. 8. Verify that the red light on the SST (Deployment tool) is illuminated. 9. Make sure all persons are standing at least 6 m {20 ft} away from the vehicle. A6E8130W032 10. Press the activation switch on the SST (Deployment tool) to deploy the driver-side air bag module. 11.
AIR BAG SYSTEM 4. Tie the passenger-side air bag module to the tire with the module facing the center of the tire. Wrap the wire harness through the tire and around the bolts at least four times. Warning • If the air bag module ia not properly installed to the tire, serious injury may occur when the module is deployed, When installing the air bag module to the tire, make sure the module is facing the center of the tire. A6E8130W036 5.
AIR BAG SYSTEM Side air bag module 1. Remove the side air bag module. (See T121 SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 2. Connect the SST (Adapter harness) to the side air bag module as shown in the figure. A6E8130W016 3. Tie the side air bag module to the tire with the module facing the center of the tire. Wrap the wire harness through the tire and around the bracket at least four times.
AIR BAG SYSTEM 6. Control the SST (Deployment tool) to the SST (Adapter harness). 7. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal. 8. Verify that the red light on the SST (Deployment tool) is illuminated. 9. Make sure all persons are standing at least 6 m {20 ft} from the vehicle. A6E8130W054 10. Press the activation switch on the SST (Deployment tool) to deploy the side air bag module.
AIR BAG SYSTEM 4. Tie the side air bag module to the tire with the module facing the center of the tire. Wrap the wire harness through the tire and around the bracket at least four times. Warning • If the air bag module is not properly installed to the tire, serious injury may occur when the module is deployed. When installing the air bag module to the tire, make sure the module is facing the downward. A6E8130W018 5. Connect the SST (Adapter harness) to the curtain air bag module as shown in the figure.
AIR BAG SYSTEM 8. Control the SST (Deployment tool) to the SST (Adapter harness). 9. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal. 10. Verify that the red light on the SST (Deployment tool) is illuminated. 11. Make sure all persons are standing at least 6 m {20 ft} from the vehicle. A6E8130W055 12. Press the activation switch on the SST (Deployment tool) to deploy the curtain air bag module.
AIR BAG SYSTEM 4. Stack the tire with the pre-tensioner seat belt on top of two tires. Stack a tire on top of the three tires. Stack another tire that has a wheel on top of the four tires. A6E8130W039 5. Tie all tires together with wire. A6E8130W034 6. Connect the SST (Deployment tool) to the SST (Adapter harness). 7. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal. 8.
AIR BAG SYSTEM • The deployed air bag module and pre-tensioner seat belt may contain deposits of sodium hydroxide, a caustic byproduct of the gas-generated combustion. If this substance gets into your eyes or on your hands, it can cause irritation and itching. When handling the deployed air bag module and pre-tensioner seat belt, wear gloves and safety glasses.
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] MULTIPLEX COMMUNICATION SYSTEM A6E816255430W01 Outline • In case the controller area network (CAN) system is malfunctioning, read the DTCs of the following modules, using the SST (WDS or equivalent) to determine the malfunctioning system.
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] DTC TABLE DTC U0073 U0121 U0155 U1900 U2516 A6E816255430W02 Malfunction location Related module CAN system communication error Communication error to ABS (ABS/TCS) HU/CM PCM or DSC HU/CM Communication error to instrument cluster CAN system communication error • ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS) CAN system wiring harness open and short • DSC HU/CM (with DSC) circuit • Instrument cluster Page (See T144 DTC U0073, U1900, U2516) (See T144 DTC
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] PCM 1. Check the display of DTC U0121 and/or U0155, using the SST (WDS or equivalent). (See T142 DTC TABLE.) 2. Referring to the following table, determine the malfunctioning part of the CAN system.
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] DTC U0073, U1900, U2516 DTC U0073 U1900 U2516 DETECTION CONDITION CAN system communication error CAN system wiring harness open and short circuit Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system. When performing inspection, always follow inspection procedure.
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION 6 INSPECT WIRING HARNESS BETWEEN DSC HU/CM AND INSTRUMENT CLUSTER • Disconnect DSC HU/CM connector. • Inspect following wiring harness between DSC HU/CM and instrument cluster terminals for short to ground, short power supply, and open circuit: AF2W (CAN_L) AG2X (CAN_H) • Is wiring harness okay? 7 INSPECT WIRING HARNESS BETWEEN ABS (ABS/TCS) HU/CM AND INSTRUMENT CLUSTER • Disconnect ABS (ABS/TCS) HU/CM connector.
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION 14 INSPECT WIRING HARNESS BETWEEN PCM AND DSC HU/CM • Disconnect negative battery cable. • Disconnect DSC HU/CM connector. • Inspect following wiring harness between PCM and DSC HU/CM terminals for short to ground, short power supply, and open circuit: 2RAF (CAN_L) 2UAG (CAN_H) • Is wiring harness okay? 15 INSPECT WIRING HARNESS BETWEEN PCM AND ABS (ABS/TCS) HU/CM • Disconnect negative battery cable.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] FOREWORD A6E816467000W01 Outline • The OBD (on-board diagnostic) test inspects the integrity and function of the headlight auto leveling system and output the results when reqested by the specitic tests. • OBD test also: Provides a quick inspection of the headlight auto leveling system. Is usually performed at the start of each deagnostic procedure.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC TABLE A6E816467000W02 • DTCs are common for present and past malfunction diagnosis. DTC B1342 B2141 B2390 B2477 B2607 B2615 B2616 B2619 B2626 B2735 Description Auto leveling control unit system. Configuration setting system for auto leveling control unit. Communication system between auto leveling control unit (main) and auto leveling contro unit (sub). Auto leveling control unit setting system. Auto leveling control unit controlling system.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC B2390 DTC B2390 DETECTION CONDITION POSSIBLE CAUSE A6E816467000W05 Communication system between auto leveling control unit (main) and auto leveling control unit (sub). Warning • incorrect servicing of the auto leveling control unit could result in electrical shock because the unit is integrated with the discharge headlight control unit. Before servicing the auto leveling control unit, always refer to Discharge headlight service warnings.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] Diagnostic procedure STEP 1 2 3 INSPECTION ACTION Go to next step. After correcting fit, clear DTC and check DTC again. • If DTC is displayed again, go to next step. INSPECT CONNECTOR CONNECTION Yes No INSPECT HEADLIGHT (LH) AND HEADLIGHT (RH) Yes No Go to next step. Possible cause is an open circuit in headlight. Replace headlight (LH) or headlight (RH).
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC B2607 DTC B2607 DETECTION CONDITION POSSIBLE CAUSE A6E816467000W06 Auto leveling control unit controlling system. Warning • incorrect servicing of the auto leveling control unit could result in electrical shock because the unit is integrated with the discharge headlight control unit. Before servicing the auto leveling control unit, always refer to Discharge headlight service warnings.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] Diagnostic procedure for headlight (LH) STEP 1 2 3 INSPECTION ACTION Go to next step. After correcting fit, clear DTC and check DTC again. • If DTC is displayed again, go to next step. INSPECT CONNECTION Yes No INSPECT WIRING HARNESS BETWEEN AUTO LEVELING SENSOR CONNECTORS AND HEADLIGHT (LH) CONNECTOR Yes No Go to next step. Repair or replace wiring harness between front auto leveling sensor and headlight (LH).
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC B2615 DTC B2615 DETECTION CONDITION POSSIBLE CAUSE A6E816467000W07 Front or rear auto leveling sensors power supply system. Warning • incorrect servicing of the auto leveling control unit could result in electrical shock because the unit is integrated with the discharge headlight control unit. Before servicing the auto leveling control unit, always refer to Discharge headlight service warnings.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] Diagnostic procedure STEP 1 2 INSPECTION Yes No Go to next step. Go to step 4. INSPECT POWER SUPPLY CIRCUIT OF FRONT AUTO LEVELING SENSOR Yes Replace front auto leveling sensor. (See T32 FRONT AUTO LEVELING SENSOR REMOVAL/ INSTALLATION) After replacement, clear DTC and check DTC again. • If DTC is displayed again, go to next step. Repair or replace wiring harness between front auto leveling sensor and headlight (LH).
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC B2616 DTC B2616 DETECTION CONDITION POSSIBLE CAUS A6E816467000W08 Front auto leveling sensor signal system. Warning • incorrect servicing of the auto leveling control unit could result in electrical shock because the unit is integrated with the discharge headlight control unit. Before servicing the auto leveling control unit, always refer to Discharge headlight service warnings.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] Diagnostic procedure STEP 1 2 3 4 5 INSPECTION ACTION Go to next step. After correcting fit, clear DTC and check DTC again. • If DTC is displayed again, go to next step. INSPECT FRONT LEVELING SENSOR CONNECTION Yes No INSPECT WIRING HARNESS BETWEEN FRONT AUTO LEVELING SENSOR CONNECTOR AND HEADLIGHT (LH) CONNECTOR Yes No Go to next step. Repair or replace wiring harness between front auto leveling sensor and headlight (LH).
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC B2619 DTC B2619 DETECTION CONDITION POSSIBLE CAUSE A6E816467000W09 Rear auto leveling sensor signal system. Warning • incorrect servicing of the auto leveling control unit could result in electrical shock because the unit is integrated with the discharge headlight control unit. Before servicing the auto leveling control unit, always refer to Discharge headlight service warnings.
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] STEP 3 4 5 INSPECTION ACTION Go to next step. Repair or replace wiring harness between rear auto leveling sensor and headlight (LH). INSPECT WIRING HARNESS BETWEEN REAR AUTO LEVELING SENSOR CONNECTOR AND HEADLIGHT (LH) CONNECTOR Yes No INSPECT HEADLIGHT (LH) Yes No Go to next step. Possible cause is an open circuit in headlight (LH). Replace headlight (LH).
ON-BOARD DIAGNOSTIC [HEADLIGHT AUTO LEVELING SYSTEM] DTC B2735 DTC B2735 DETECTION CONDITION POSSIBLE CAUSE A6E816467000W11 Headlight leveling actuator signal system. Warning • incorrect servicing of the auto leveling control unit could result in electrical shock because the unit is integrated with the discharge headlight control unit. Before servicing the auto leveling control unit, always refer to Discharge headlight service warnings.
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] FOREWORD A6E817067000W01 Caution • When the engine does not start or stalls and the following DTCs are not indicated, go to engine symptom troubleshooting. Note • When the immobilizer system is defective, the engine cannot be started. • If engine condition is normal but light stays on, inspect for short circuit between security light. Repair or replace the wiring harness if necessary. 1. 2. 3. 4. 5.
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] Note • Perform the following if the security light stays on: If gasoline engine stalls, go to symptom troubleshooting NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES in. (See F204 NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/ STUMBLE, SURGES.) If gasoline engine wont start, go to symptom troubleshooting NO.6 CRANKS NORMALLY BUT WILL NOT START in. (See F195 NO.
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] STEP INSPECTION 6 INSPECT COIL OUTPUT SIGNAL CIRCUIT • Connect coil and PCM connectors. • Turn ignition switch to ON position. • Measure voltage at terminal A of coil connector. • Is voltage more than 9 V? 7 INSPECT COIL OUTPUT SIGNAL CIRCUIT • Turn ignition switch to OFF position. • Disconnect PCM connector. • Measure resistance between PCM connector terminal 2Q and ground.
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] DTC B1600 A6E817067000W05 DTC B1600 POSSIBLE CAUSE ID number is not input into PCM. • No transponder in the key • Defective transponder in the key (ID number is not output.) Diagnostic procedure STEP INSPECTION 1 REPROGRAM NEW KEY • Register new key. (See T90 IMMOBILIZER SYSTEM REPROGRAM PROCEDURE) • Clear DTCs with WDS or equivalent. • Turn ignition switch to ON position with new key. Yes No ACTION Go to next step. Immobilizer system is okay.
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] End Of Sie DTC B1601 A6E817067000W08 DTC B1601 POSSIBLE CAUSE PCM received incorrect ID number from key (transponder). • Defective transponder in the key Diagnostic procedure STEP INSPECTION INSPECT KEYS • Turn ignition switch to ON position with first encoded key for 3 seconds. • Turn ignition switch to ON position with second encoded key for 3 seconds. • Turn ignition switch to START position with second encoded key.
ON-BOARD DIAGNOSTIC [AUDIO] ON-BOARD DIAGNOSTIC [AUDIO] STARTING PROCEDURE FOR ON-BOARD DIAGNOSTIC TEST MODE A6E817566900W01 Note • All DTCs displayed in the on-board diagnostic test mode should be entered in the Audio Repair Order Form. 1. Turn the ignition switch to the ACC or ON position. 2. First press the POWER button, then simultaneously press the AM button and TAPE/ MD button for 2 seconds or more.
ON-BOARD DIAGNOSTIC [AUDIO] DTC CLEARING PROCEDURE A6E817566900W03 1. Start the on-board diagnostic test mode. 2. First press the POWER button, then simultaneously press AUDIO CONT button for 2 seconds or more. 1 2 POWER button (type A) AUDIO CONT button (type B) AUDIO CONT button (type A) POWER button (type B) Caution • Before clearing the DTCs, be sure to enter all of them displayed in the onboard diagnostic test mode in the Audio Repair Order Form. A6E8175W009 3.
ON-BOARD DIAGNOSTIC [AUDIO] Diagnostic procedure INSPECTION INSPECT BASE UNIT • Clear DTC. • Turn on radio and operate it for 3 seconds or more. • Start on-board diagnostic test mode. • Is DTC 09:Er22 displayed? Yes No ACTION Replace base unit. Troubleshooting completed. End Of Sie DTC 09:ER20 DTC 09:Er20 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W06 Power supply circuit of base unit • Voltage detected at base unit terminals 1B and 1R is less than 8.5 V, or more than 16 V (must not be 16V).
ON-BOARD DIAGNOSTIC [AUDIO] DTC 00:ER10 End Of Sie DTC 00:Er10 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W07 Cassette deckbase unit communication line • Base unit detects communication error with cassette deck. • Malfunction of connectors between base unit and cassette deck • Cassette deck malfunction • Base unit malfunction Diagnostic procedure STEP INSPECTION 1 INSPECT CONNECTOR • Remove cassette deck and inspect connector for the following.
ON-BOARD DIAGNOSTIC [AUDIO] DTC 05:ER10 DTC 05:Er10 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W09 CD changer (external type)base unit communication line • Base unit detects communication error with CD changer (external type). • Malfunction of connectors between base unit and CD changer (external type) • CD changer (external type) malfunction • Base unit malfunction Diagnostic procedure STEP INSPECTION 1 INSPECT CONNECTOR • Inspect base unit and CD changer (external type) connectors for connection.
ON-BOARD DIAGNOSTIC [AUDIO] DTC 07:ER10 DTC 07:Er10 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W11 MD playerbase unit communication line • Base unit detects communication error with MD player. • Malfunction of connectors between base unit and MD player • MD player malfunction • Base unit malfunction Diagnostic procedure STEP INSPECTION 1 INSPECT CONNECTOR • Remove MD player and inspect connector for the following.
ON-BOARD DIAGNOSTIC [AUDIO] Diagnostic procedure STEP INSPECTION 1 VERIFY WHETHER MALFUNCTION IS IN CD PLAYER OR CD • Play CD and select other song (change tracks). • Does CD player change tracks? 2 3 INSPECT CD • Inspect condition of CD where error has occurred. • Is CD okay? INSPECT CD PLAYER • Clear DTC. • Play CD and select other song (change tracks). • Start on-board diagnostic test mode. • Is DTC 03:Er02 displayed? Yes No Yes No Yes No ACTION Go to Step 3.
ON-BOARD DIAGNOSTIC [AUDIO] STEP INSPECTION 3 INSPECT CASSETTE DECK • Clear DTC. • Insert and eject cassette tape with no defect. • Start on-board diagnostic test mode. • Is DTC 00:Er01 displayed? Yes No ACTION Replace cassette deck. Troubleshooting completed. End Of Sie DTC 00:ER03 DTC 00:Er03 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W16 Cassette deck • Base unit detects that reel built into cassette deck does not operate.
ON-BOARD DIAGNOSTIC [AUDIO] Diagnostic procedure STEP INSPECTION 1 VERIFY WHETHER MALFUNCTION IS IN CD CHANGER OR OTHER PARTS • Operate changer function. • Is function okay? 2 3 4 INSPECT CD • Inspect condition of CD where error has occurred. • Is CD okay? INSPECT MAGAZINE • Inspect magazine. • Is magazine okay? INSPECT CD CHANGER (EXTERNAL TYPE) • Clear DTC. • Operate changer. • Start on-board diagnostic test mode. • Is DTC 05:Er01 displayed? Yes No Yes No ACTION Go to Step 4.
ON-BOARD DIAGNOSTIC [AUDIO] STEP INSPECTION 3 INSPECT CD CHANGER (UPPER MODULE) • Clear DTC. • Insert and eject CD with no defect. • Start on-board diagnostic test mode. • Is DTC 06:Er01 displayed? Yes No ACTION Replace CD changer (upper module). Troubleshooting completed. End Of Sie DTC 06:ER02 DTC 06:Er02 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W21 CD changer (upper module) Note • When error occurs, error message CHECK CD is displayed in the LCD. • Cannot play CD normally or change tracks.
ON-BOARD DIAGNOSTIC [AUDIO] STEP INSPECTION 3 INSPECT CD CHANGER (UPPER MODULE) • Clear DTC. • Insert and play CD for 12 seconds or more. • Start on-board diagnostic test mode. • Is DTC 06:Er07 displayed? Yes No ACTION Replace CD changer (upper module). Troubleshooting completed. End Of Sie DTC 07:ER01 DTC 07:Er01 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W23 MD player • MD player cannot implement insert and eject commands.
ON-BOARD DIAGNOSTIC [AUDIO] DTC 07:ER07 DTC 07:Er07 DETECTION CONDITION POSSIBLE CAUSE A6E817566900W25 MD player Note • When error occurs, error message CHECK MD is displayed in the LCD. • Base unit detects MD reading error. • Defective MD (scratches or dirt) • MD player malfunction Diagnostic procedure STEP INSPECTION 1 INSPECT MD • Inspect condition of MD where error has occurred. • Is MD okay? 2 INSPECT MD PLAYER • Clear DTC. • Insert and play MD for 12 seconds or more.
ON-BOARD DIAGNOSTIC [AUDIO] LCD Inspection 1. With audio on, first press the POWER button, then simultaneously press the SEEK button (upper) for approximately 1 second. 2. Inspect the LCD according to the following table: Inspection Start LCD inspection mode. Display Action Characters displayed in LCD LCD is okay. are not truncated or faint. Other than above. Replace base unit. 3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function. Button Inspection 1.
ON-BOARD DIAGNOSTIC [AUDIO] Audio Amplifier (External) Inspection 1. With audio on, first press the POWER button, then simultaneously press the SCAN button for approximately 1 second. 2. Inspect the audio amplifier (external) according to the following table: Inspection Start audio amplifier (external) inspection mode. Display Speakers output sound. Speakers do not output sound. Action System is okay. Inspect following parts.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] FOREWORD A6E817266350W01 Outline • There are two on-board diagnostic functions: Operation mode, which inspects for and indicates correct operation of the input signals to the control module, and condition detection mode, which indicates troubles in the system.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] 3. Press and hold the RESUME/ACCEL switch on (1), and turn on the cruise control main switch (2). Keep the RESUME/ACCEL switch on for 3 seconds or more after the cruise control main switch released. (The cruise set indicator light will illuminate for 3 seconds, showing that the system inspection has started.) 4. Operate each switch as described in the operation code list and note the operation code list pattern.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] DTC 21 A6E817266350W03 DTC 21 DETECTION CONDITION POSSIBLE CAUSE Cruise control switch (SET/COAST switch) • Resistance detected between cruise actuator connector terminal J and ground is other than approximately 680 ohms.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] DTC 31 A6E817266350W05 DTC 31 DETECTION CONDITION POSSIBLE CAUSE Brake switch • Voltage detected at cruise actuator connector terminal C is not approximately 12 V or voltage detected at cruise actuator connector terminal K is not approximately 0 V.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] STEP INSPECTION *7 VERIFY WHICH IS MALFUNCTIONING CRUISE ACTUATOR AND WIRING HARNESS (BRAKE SWITCH 2 AND CRUISE ACTUATOR) OR BRAKE SWITCH 2 • Disconnect brake switch connector. • Turn ignition switch ON position. • Is voltage at brake switch connector terminal B approximately 12 V? *8 INSPECT WIRING HARNESS BETWEEN BRAKE SWITCH 2 AND CRUISE ACTUATOR FOR SHORT TO POWER SUPPLY • Turn ignition switch to LOCK position. • Disconnect cruise actuator connector.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] STEP INSPECTION 5 INSPECT TR SWITCH • Inspect TR switch. (See K14 TRANSAXLE RANGE (TR) SWITCH INSPECTION) • Is TR switch okay? *6 INSPECT WIRING HARNESS BETWEEN TR SWITCH AND GROUND FOR CONTINUITY • Disconnect TR switch connector. • Is there continuity between TR switch connector terminal A and ground? *7 INSPECT WIRING HARNESS BETWEEN CRUISE ACTUATOR AND TR SWITCH FOR CONTINUITY • Disconnect cruise actuator connector.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] INSPECTION OF DTCS FOR CONDITION DETECTION MODE End Of Sie A6E817266350W08 Note • The cruise set indicator light will illuminate for 3 seconds, when condition detection mode is on. • If the RESUME/ACCEL switch on the cruise control switch is malfunctioning, the cruise set indicator light will not give a correct indication when you inspect the system. 1. 2. 3. 4. 5. Drive the vehicle at 30 km/h {19 mph} or more. Press on the cruise control main switch (1).
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] DTC 01 DTC 01 DETECTION CONDITION POSSIBLE CAUSE A6E817266350W09 Cruise actuator (Drive circuit) • Malfunction in cruise actuator circuit (drive circuit) • Cruise actuator malfunction Diagnostic procedure ACTION REPLACE CRUISE ACTUATOR IF IT IS MALFUNCTIONING • Replace cruise actuator.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] Diagnostic procedure STEP INSPECTION 1 INSPECT BRAKE SWITCH • Disconnect brake switch connector. • Inspect brake switch. (See P8 BRAKE SWITCH INSPECTION) • Is brake switch okay? 2 INSPECT BRAKE SWITCH 2 • Inspect brake switch 2. (See P8 BRAKE SWITCH INSPECTION) • Is brake switch okay? 3 INSPECT WIRING HARNESS BETWEEN BRAKE SWITCH AND CRUISE ACTUATOR FOR CONTINUITY • Disconnect cruise actuator connector.
ON-BOARD DIAGNOSTIC [CRUISE CONTROL SYSTEM] DTC 13 DTC 13 DETECTION CONDITION POSSIBLE CAUSE A6E817266350W14 Cruise control switch (ground circuit) • Resistance detected between cruise actuator connector terminal J and ground is always approximately 0 ohm. • Cruise actuator malfunction Diagnostic procedure INSPECTION INSPECT DTC FOR OPERATION MODE • Was operation mode for DTCs 21 and 22 performed? Yes No ACTION Perform operation mode for DTCs 21 and 22 on-board diagnostic again.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] FOREWORD A6E817401046W01 Outline • The OBD (on-board diagnostic) test inspects the integrity and function of the air bag system and outputs the results when requested by the specific tests. • OBD test also: Provides a quick inspection of the air bag system. Is usually performed at the start of each diagnostic procedure. Provides verification after repairs to ensure that no other faults occurred during service.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] Flowchart • Use the following flowchart to verify the cause of the trouble. Note • While performing the inspection of the past malfunction code, the applicable DTCs may be added to memory by removing or disconnecting the related parts. Inspect only the DTCs that were indicated before inspecting.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTCs Reading Procedure 1. Connect SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector. 2. Retrieve DTC using SST (WDS or equivalent). A6E3970W002 Clearing DTCs Procedure 1. After repairs have been made, perform the DTCs reading procedure. 2. Erase DTCs using SST (WDS or equivalent). 3. Ensure that the customer's concern has been resolved. PID/Data Monitor and Record Procedure 1. Connect SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector. 2.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC TABLE A6E817401046W02 • DTCs are common for present and past malfunction diagnosis. Note • When DTCs not shown in the DTC table are displayed, replace the SAS unit. • If the air bag system warning light does not illuminate or remains illuminated when the ignition switch is turned to ON position, inspect and repair the air bag system warning light circuitry and then confirm that the air bag system warning light is operational.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC Air bag system warning light WDS or equivalent Flashing pattern Priority ranking Malfunction location Page B1885 33 13 Driver-side pre-tensioner (See T202 DTC seat belt system resistance B1877, B1878, low B1879, B1885) B1886 34 12 Passenger-side pretensioner seat belt system resistance low B1890 18 18 Passenger-side air bag cut(See T205 DTC off indicator light system B1884, B1890) circuit short to power supply 19 11 Driver-side air bag module (i
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC Air bag system warning light WDS or equivalent Flashing pattern Priority ranking Page 23 14 Passenger-side side air bag module system circuit short to power supply Passenger-side side air bag module system circuit short to ground Passenger-side side air bag module system resistance high Passenger-side side air bag module system resistance low 19 11 Driver-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC Air bag system warning light WDS or equivalent Flashing pattern B2773 B2774 Driver-side curtain air bag module system resistance low Driver-side curtain air bag module system resistance high Driver-side curtain air bag module system circuit short to ground Driver-side curtain air bag module system circuit short to power supply Passenger-side curtain air bag module system resistance low Passenger-side curtain air bag module system resistance high Passenger-side cu
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] PID name (definition) DS_AB_ST (Driver-side side air bag module circuit state) DS_CURT_ST (Driver-side curtain air bag module circuit state) DS1_STAT (Driver-side air bag module (inflator No.1) circuit state) DS2_STAT (Driver-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] PID name (definition) OD_P_PSAB_ST (On demand passenger-side side air bag sensor circuit state) P_ABAGR2 (Passenger-side air bag module (inflator No.2) resistance) P_PTENSFLT (Passenger-side pre-tensioner seat belt circuit state) PABAGR (Passenger-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1231 DTC B1231 DETECTION CONDITION A6E817401046W05 SAS unit activation (deployment) control freeze Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system. When performing inspection, always follow inspection procedure. • SAS unit determined collision Diagnostic procedure ACTION Replace SAS unit.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] Diagnostic procedure STEP INSPECTION 1 INSPECT METER IG 15 A FUSE • Turn ignition switch to LOCK position. • Disconnect negative battery cable. • Remove METER IG 15 A fuse. • Is fuse okay? 2 INSPECT FOR CONTINUITY BETWEEN METER IG 15 A FUSE AND INSTRUMENT CLUSTER • Connect negative battery cable. • Turn ignition switch to ON position. • Measure voltage at instrument cluster connector terminal 2V.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1871 End Of Sie DTC B1871 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W08 Occupancy sensor system (communication error, sensor internal circuit abnomal) Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system. When performing inspection, always follow inspection procedure.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 2 INSPECT WIRING HARNESS BETWEEN OCCUPANCY SENSOR AND SAS UNIT Yes No ACTION Go to next step. Replace wiring harness. Warning • Handling air bag system components improperly can accidentally deploy air bag modules, and pre-tensioner seat belts which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components. (See T117 SERVICE WARNINGS) 3 4 • Turn ignition switch to LOCK position.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1877, B1878, B1879, B1885 DTC B1877 B1878 B1879 B1885 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W09 Driver-side pre-tensioner seat belt system resistance high Driver-side pre-tensioner seat belt system circuit short to power supply Driver-side pre-tensioner seat belt system circuit short to ground Driver-side pre-tensioner seat belt system resistance low Warning • Detection conditions are for understanding DTC outline before performing inspection.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN DRIVER-SIDE PRE-TENSIONER SEAT BELT OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to driver-side pre-tensioner seat belt connector terminal A and B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable. • Turn ignition switch to ON position. • Check following PID/DATA monitor, using SST (WDS or equivalent).
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] Diagnostic procedure STEP INSPECTION 1 INSPECT PASSENGER-SIDE PRETENSIONER SEAT BELT • Check following PID/DATA monitor, using SST (WDS or equivalent). (See T195 PID/DATA MONITOR TABLE) PS_PTENS • Is resistant value of passenger-side pretensioner seat belt normal? Resistance: 1.53.1 ohm 2 INSPECT PASSENGER-SIDE PRETENSIONER SEAT BELT CONNECTOR ACTION Yes Present malfunction diagnosis: • Replace SAS unit.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1884, B1890 DTC B1884 B1890 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W11 Passenger-side air bag cut-off indicator light system circuit open or short to ground Passenger-side air bag cut-off indicator light system circuit short to power supply Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 4 INSPECT WIRING HARNESS BETWEEN PASSENGER-SIDE AIR BAG CUT-OFF INDICATOR LIGHT AND SAS UNIT Warning • Handling air bag system components improperly can accidentally deploy air bag modules, and pre-tensioner seat belts which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components. (See T117 SERVICE WARNINGS) 5 6 • Turn ignition switch to LOCK position.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 7 INSPECT PASSENGER-SIDE AIR BAG CUT-OFF INDICATOR LIGHT • Turn ignition switch to LOCK position. • Disconnect negative battery cable and wait for more than 1 minutes. • Remove center panel module. (See T96 CENTER PANEL MODULE REMOVAL/INSTALLATION) • Inspect continuity wiring harness between passenger-side air bag cut-off indicator light terminals A and B.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1913, B1916, B1932, B1934 DTC B1913 B1916 B1932 B1934 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W12 Driver-side air bag module (inflator No.1) system circuit short to ground Driver-side air bag module (inflator No.1) system circuit short to power supply Driver-side air bag module (inflator No.1) system resistance high Driver-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN DRIVER-SIDE AIR BAG MODULE (INFLATOR NO.1) OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to driver-side air bag module (inflator No.1) connector terminal 3A and 3B, and driver-side air bag module (inflator No.2) connector terminal 4A and 4B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1913, B1925, B1933, B1935 DTC B1913 B1925 B1933 B1935 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W13 Passenger-side air bag module (inflator No.1) system circuit short to ground Passenger-side air bag module (inflator No.1) system circuit short to power supply Passenger-side air bag module (inflator No.1) system resistance high Passenger-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN PASSENGER-SIDE AIR BAG MODULE (INFLATOR NO.1) OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to passenger-side air bag module (inflator No.1) connector terminal A and B, and passenger-side air bag module (inflator No.2) connector terminal A and B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B1992, B1993, B1994, B1995 DTC B1992 B1993 B1994 B1995 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W15 Driver-side side air bag module system circuit short to power supply Driver-side side air bag module system circuit short to ground Driver-side side air bag module system resistance high Driver-side side air bag module system resistance low Warning • Detection conditions are for understanding DTC outline before performing inspection.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN DRIVER-SIDE SIDE AIR BAG MODULE OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to driver-side side air bag module connector terminal A and B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable. • Turn ignition switch to ON position. • Check following PID/DATA monitor, using SST (WDS or equivalent).
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] Diagnostic procedure STEP INSPECTION 1 INSPECT PASSENGER-SIDE SIDE AIR BAG MODULE • Check following PID/DATA monitor, using SST (WDS or equivalent). (See T195 PID/DATA MONITOR TABLE) PS_AB • Is resistant value of passenger-side side air bag module normal? Resistance: 1.43.2 ohm 2 INSPECT PASSENGER-SIDE SIDE AIR BAG MODULE CONNECTOR ACTION Yes Present malfunction diagnosis: • Replace SAS unit.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B2228, B2230, B2232, B2234 DTC B2228 B2230 B2232 B2234 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W17 Driver-side air bag module (inflator No.2) system circuit short to ground Driver-side air bag module (inflator No.2) system circuit short to power supply Driver-side air bag module (inflator No.2) system resistance high Driver-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN DRIVER-SIDE AIR BAG MODULE (INFLATOR NO.2) OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to driver-side air bag module (inflator No.1) connector terminal 3A and 3B, and driver-side air bag module (inflator No.2) connector terminal 4A and 4B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B2229, B2231, B2233, B2235 DTC B2229 B2231 B2233 B2235 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W18 Passenger-side air bag module (inflator No.2) system circuit short to ground Passenger-side air bag module (inflator No.2) system circuit short to power supply Passenger-side air bag module (inflator No.2) system resistance high Passenger-side air bag module (inflator No.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN PASSENGER-SIDE AIR BAG MODULE (INFLATOR NO.2) OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to passenger-side air bag module (inflator No.1) connector terminal A and B, and passenger-side air bag module (inflator No.2) connector terminal A and B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] Diagnostic procedure STEP INSPECTION 1 INSPECT CRASH ZONE SENSOR • Check following PID/DATA monitor, using SST (WDS or equivalent). (See T195 PID/DATA MONITOR TABLE) OD_F_CRSH • Is crash zone sensor normal? 2 INSPECT WIRING HARNESS BETWEEN CRASH ZONE SENSOR AND SAS UNIT Warning • Handling air bag system components improperly can accidentally deploy air bag modules and pre-tensioner seat belts, which may seriously injure you.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B2444, U2017 DTC B2444 U2017 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W20 Driver-side side air bag sensor system (sensor internal circuit abnormal) Driver-side side air bag sensor system (communication error) Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 2 INSPECT WIRING HARNESS BETWEEN DRIVER-SIDE SIDE AIR BAG SENSOR AND SAS UNIT Warning • Handling air bag system components improperly can accidentally deploy air bag modules and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components. (See T117 SERVICE WARNINGS) 3 • Turn ignition switch to LOCK position. • Disconnect negative battery cable and wait for more than 1 minute.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B2445, U2018 DTC B2445 U2018 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W21 Passenger-side side air bag sensor system (sensor internal circuit abnormal) Passenger-side side air bag sensor system (communication error) Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 2 INSPECT WIRING HARNESS BETWEEN PASSENGER-SIDE AIR BAG SENSOR AND SAS UNIT Warning • Handling air bag system components improperly can accidentally deploy air bag modules and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components. (See T117 SERVICE WARNINGS) 3 • Turn ignition switch to LOCK position. • Disconnect negative battery cable and wait for more than 1 minute.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B2477 DTC B2477 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W22 SAS unit configuration error Warning • Detection conditions are for understanding DTC outline before performing inspection. Performing inspection with only detection conditions may cause injury due to operating error or damage the system. When performing inspection, always follow inspection procedure.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 2 INSPECT DRIVER-SIDE CURTAIN AIR BAG MODULE CONNECTOR ACTION Yes No Replace wiring harness. Go to next step. Yes Replace driver-side curtain air bag module. (See T122 CURTAIN AIR BAG MODULE REMOVAL/ INSTALLATION) Replace wiring harness, then go to next step. Warning • Handling air bag system components improperly can accidentally deploy air bag modules and pre-tensioner seat belts, which may seriously injure you.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] DTC B2777, B2778, B2779, B2780 DTC B2777 B2778 B2779 B2780 DETECTION CONDITION POSSIBLE CAUSE A6E817401046W24 Passenger-side curtain air bag module system resistance low Passenger-side curtain air bag module system resistance high Passenger-side curtain air bag module system circuit short to ground Passenger-side curtain air bag module system circuit short to power supply Warning • Detection conditions are for understanding DTC outline before performing inspection.
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] STEP INSPECTION 3 VERIFY WHETHER MALFUNCTION IS IN PASSENGER-SIDE CURTAIN AIR BAG MODULE OR RELATED WIRING HARNESS • Connect leads of SST (Fuel and thermometer checker) or apply 2 ohm resistor to passenger-side curtain air bag module connector terminal A and B. • Set resistance of SST (Fuel and thermometer checker) to 2 ohm. • Connect negative battery cable. • Turn ignition switch to ON position. • Check following PID/DATA monitor, using SST (WDS or equivalent).
ON-BOARD DIAGNOSTIC [AIR BAG SYSTEM] Diagnostic procedure STEP INSPECTION 1 VERIFY THAT ALL SAS UNIT CONNECTORS ARE CONNECTED WITH SAS UNIT Yes No ACTION Go to next step. Reconnect connector properly. Yes Present malfunction diagnosis: Warning • Handling air bag system components improperly can accidentally deploy air bag modules and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components.
TROUBLESHOOTING TROUBLESHOOTING CAR-NAVIGATION SYSTEM Troubleshooting Index • Use the chart below verify the trouble in order to diagnose the appropriate area. No. 1 2 3 A6E818066000W01 Malfunction symptom While vehicle is in reverse, vehicle locator mark goes forward. In navigation mode, vehicle locator mark skips. Even when headlight switch is turned on, daytime screen does not change to night time screen. (Front and rear combination lights operate normally.) End Of Sie NO.
TROUBLESHOOTING Diagnostic procedure STEP 1 2* INSPECTION • Disconnect car-navigation unit connector (16-pin). • Jack up vehicle and run engine at low speed. • Measure voltage at the following terminal of car-navigation unit connector (16-pin): Terminal 2H (Vehicle speed signal) • Is voltage approx. 2.5 V (reference)? • • 3 4 • • • Note • Vehicle speed signal is in electrical pulses of approx. 0 V to 5 V. Disconnect ABS (ABS/TCS) HU/CM connector (28-pin) or DSC HU/CM connector (34-pin).
TROUBLESHOOTING No. 2 Troubleshooting item Air bag system warning light is illuminated all the time. 3 Passenger-side air bag cut-off indicator light does not illuminate. 4 Passenger-side air bag cut-off indicator light is illuminated all the time. Description Malfunction in air bag system warning circuit (open circuit or short to power supply). Malfunction in passenger-side air bag cut-off indicator light circuit (open circuit or short to power supply).
TROUBLESHOOTING STEP INSPECTION *3 INSPECT WIRING HARNESS BETWEEN SAS UNIT AND INSTRUMENT CLUSTER FOR SHORT TO GROUND • Turn ignition switch to LOCK position. • Disconnect negative battery cable. • Disconnect instrument cluster connector. • Is there continuity between terminal 1O of instrument cluster connector and ground? 4 INSPECT INSTRUMENT CLUSTER • Connect instrument cluster connector. • Connect instrument cluster connector terminal 1O to ground, then reconnect connector.
TROUBLESHOOTING STEP INSPECTION 2 VERIFY THAT SAS unit CONNECTOR IS CONNECTED Yes No ACTION Go to next step. Reconnect connector properly, then go to Step 10. Yes No Go to next step. Replace wiring harness, then go to Step 10. Warning • Handling air bag system components improperly can accidentally deploy air bag modules and pre-tensioner seat belts, which may seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components.
TROUBLESHOOTING STEP INSPECTION 6 INSPECT POWER SUPPLY CIRCUIT OF SAS UNIT (TERMINAL 1W) • Turn ignition switch to LOCK position. • Disconnect negative battery cable and wait for more than 1 minute. • Connect all SAS unit connectors. • Connect driver and passenger-side pre-tensioner seat belt connectors. (Vehicles with pre-tensioner seat belt) • Connect driver and passenger-side curtain air bag module connectors.
TROUBLESHOOTING STEP INSPECTION 10 CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Turn ignition switch to LOCK position. • Disconnect negative battery cable and wait for more than 1 minute. • Connect all SAS unit connectors. • Connect driver and passenger-side pre-tensioner seat belt connectors. (Vehicles with pre-tensioner seat belt) • Connect driver and passenger-side curtain air bag module connectors.
TROUBLESHOOTING STEP INSPECTION *2 INSPECT WIRING HARNESS BETWEEN PASSENGER-SIDE AIR BAG CUT-OFF INDICATOR LIGHT AND SAS UNIT FOR CONTINUITY Yes No ACTION Go to next step. Replace wiring harness, then go to Step 5. Yes No Replace wiring harness, then go to Step 5. Go to next step. Yes Replace SAS unit, then go to next step. (See T124 SAS UNIT REMOVAL/INSTALLATION) Go to next step.
TROUBLESHOOTING STEP INSPECTION 5 CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Turn ignition switch to LOCK position. • Disconnect negative battery cable and wait for more than 1 minute. • Connect all SAS unit connectors. • Connect driver and passenger-side pre-tensioner seat belt connectors. (Vehicles with pre-tensioner seat belt) • Connect driver and passenger-side curtain air bag module connectors.
TROUBLESHOOTING STEP INSPECTION 2 CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Connect all SAS unit connectors. • Connect driver and passenger-side pre-tensioner seat belt connectors. (Vehicles with pre-tensioner seat belt) • Connect driver and passenger-side curtain air bag module connectors. (Vehicles with curtain air bag) • Connect driver and passenger-side side air bag module connectors. (Vehicles with side air bag) • Connect passenger-side air bag module connector.
HEATER AND AIR CONDITIONER SYSTEMS U LOCATION INDEX .................................................U-3 BASIC SYSTEM ..................................................U-3 CONTROL SYSTEM............................................U-4 SERVICE WARNINGS ...........................................U-8 HANDLING REFRIGERANT................................U-8 STORING REFRIGERANT..................................U-8 SERVICE CAUTIONS.............................................
DTC 07, 11, 13, 15, 19, 22 (WHEN TWO OR MORE DTCS ARE INDICATED AT THE SAME TIME) ...................................................U-63 DTC 19, 22 (WHEN TWO OR MORE DTCS ARE INDICATED AT THE SAME TIME).........U-63 TROUBLESHOOTING..........................................U-64 FOREWORD......................................................U-64 TROUBLESHOOTING INDEX ...........................U-64 NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM VENTS ..................................U-65 NO.
LOCATION INDEX LOCATION INDEX BASIC SYSTEM A6E850001040W01 A6E8500W001 U A6E8500W002 .
LOCATION INDEX CONTROL SYSTEM End Of Sie L.H.D. A6E850001042W01 A6E8500W003 A6E8500W004 .
LOCATION INDEX 1 2 3 4 5 6 7 8 9 Air intake actuator (See U30 AIR INTAKE ACTUATOR REMOVAL/ INSTALLATION) (See U30 AIR INTAKE ACTUATOR INSPECTION) Air mix actuator (See U31 AIR MIX ACTUATOR REMOVAL/ INSTALLATION) (See U32 AIR MIX ACTUATOR INSPECTION) Airflow mode actuator (See U33 AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION) (See U34 AIRFLOW MODE ACTUATOR INSPECTION) Blower motor (See U35 BLOWER MOTOR REMOVAL/ INSTALLATION) (See U35 BLOWER MOTOR INSPECTION) Resistor (See U35 RESISTOR REMOVAL/
LOCATION INDEX R.H.D. A6E8500W005 A6E8500W006 .
LOCATION INDEX 1 2 3 4 5 6 7 8 9 Air intake actuator (See U30 AIR INTAKE ACTUATOR REMOVAL/ INSTALLATION) (See U30 AIR INTAKE ACTUATOR INSPECTION) Air mix actuator (See U31 AIR MIX ACTUATOR REMOVAL/ INSTALLATION) (See U32 AIR MIX ACTUATOR INSPECTION) Airflow mode actuator (See U33 AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION) (See U34 AIRFLOW MODE ACTUATOR INSPECTION) Blower motor (See U35 BLOWER MOTOR REMOVAL/ INSTALLATION) (See U35 BLOWER MOTOR INSPECTION) Resistor (See U35 RESISTOR REMOVAL/
SERVICE WARNINGS , SERVICE CAUTION SERVICE WARNINGS HANDLING REFRIGERANT A6E851001039W01 • Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, we urge use of recovery/recycling/recharging equipment when draining R-134a from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service.
REFRIGERANT SYSTEM SERVICE PROCEDURES REFRIGERANT SYSTEM SERVICE PROCEDURES GAS CHARGING SET INSTALLATION A6E851401039W01 1. Fully close the valves of the SST (49 C061 001). 2. Connect the SSTs (49 C061 002, 49 C061 003) to the high- and low-pressure side joints of the SST (49 C061 001). 3. Connect the SSTs (49 C061 006A, 49 C061 007) to the ends of the SSTs (49 C061 002, 49 C061 003). 4. Connect the SSTs (49 C061 006A, 49 C061 007) to the charging valves.
REFRIGERANT SYSTEM SERVICE PROCEDURES Evacuation 1. Open all the valves of the SST (49 C061 001). Caution • Close the SST (49 C061 001) valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner. 2. Start the vacuum pump and let it operate for 15 minutes. A6E8514W005 3.
REFRIGERANT SYSTEM SERVICE PROCEDURES 3. Open the high-pressure side valve of the SST (49 C061 001). A6E8514W007 4. When the low-pressure side reading increases to 0.098 MPa {1.0 kgf/cm2, 14 psi}, close the high-pressure side valve of the SST (49 C061 001). 5. Inspect for leakage from the cooler pipe/hose connections using the SST (gas leak tester). • If there is no leakage, go to Step 7. • If leakage is found at a loose joint, tighten the joint, then go to next step. 6. Inspect for leakage again.
REFRIGERANT SYSTEM SERVICE PROCEDURES 10. Open the low-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the weight of the refrigerant tank has decreased regular amount from the amount in Step 2. 11. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank. 12. Stop the engine and A/C compressor. A6E8514W010 Leak Test 1. Inspect for leakage using the SST (gas leak tester). • If there is no leakage, go to Step 3.
REFRIGERANT SYSTEM SERVICE PROCEDURES 10. Verify that the intersection of the pressure reading of the SST (49 C061 001) and ambient temperature is in the shaded zone. • If not as specified, troubleshoot the refrigerant system. (See U64 TROUBLESHOOTING INDEX.) A6E8514W001 End Of Sie REFRIGERANT SYSTEM PERFORMANCE TEST A6E851401039W02 1. Perform refrigerant pressure check. (See U12 REFRIGERANT PRESSURE CHECK.) • If they are correct, go to next step.
BASIC SYSTEM BASIC SYSTEM BLOWER UNIT REMOVAL/INSTALLATION 1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the dashboard. (See S82 DASHBOARD REMOVAL/INSTALLATION.) Remove the A/C unit. (See U15 A/C UNIT REMOVAL/INSTALLATION.) Remove the blower unit. Install in the reverse order of removal. A6E851661140W01 A6E8516W001 End Of Sie BLOWER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. A6E851661140W02 Caution • Apply only the specified grease to the link.
BASIC SYSTEM AIR FILTER REMOVAL/INSTALLATION 1. Remove the glove compartment. 2. Remove in the order indicated in the table. 1 2 A6E851661140W03 Air filter cover Air filter 3. Install in the reverse order of removal. A6E8516W018 End Of Sie AIR FILTER INSPECTION 1. Remove the air filter. 2. Inspect the air filter. • If the air filter is damaged, excessively dirty, or foul smelling, replace the air filter.
BASIC SYSTEM 6. Remove in the order indicated in the table. Do not allow compressor oil to spill.
BASIC SYSTEM A6E8516W019 . 1 2 3 4 Heater hose Cooler hose (Lo) (L.H.D.) or cooler pipe No.4 (R.H.D.) (See U28 Refrigerant Lines Removal Note) (See U29 Refrigerant Lines Installation Note) Cooler pipe No.3 (See U28 Refrigerant Lines Removal Note) (See U29 Refrigerant Lines Installation Note) A/C unit (See U17 A/C Unit Installation Note) 7. Install in the reverse order of removal. 8. Perform the refrigerant system performance test. (See U13 REFRIGERANT SYSTEM PERFORMANCE TEST.
BASIC SYSTEM A/C UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
BASIC SYSTEM A6E8516W006 . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Duct (1) Polyurethane protector (1) Polyurethane protector (2) (R.H.D.
BASIC SYSTEM Evaporator Temperature Sensor Assembly Note 1. Assemble the evaporator temperature sensor as shown in the figure. A6E8516W020 A6E8516W021 Sensor Clamp Assembly Note 1. Attach the sensor clamp as shown in the figure. A6E8516W007 Expansion Valve Assembly Note 1. Attach the insulator as shown in the figure.
BASIC SYSTEM Outlet Pipe Assembly Note 1. Wrap the insulator around the outlet pipe as shown in the figure. A6E8516W028 A6E8516W031 End Of Sie EXPANSION VALVE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (See U9 RECOVERY.) (See U9 CHARGING.) A6E851661130W03 Caution • If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur.
BASIC SYSTEM 10. Remove the expansion valve. Do not allow compressor oil to spill. A6E8516W010 11. Install in the reverse order of removal. 12. Perform the refrigerant system performance test. (See U13 REFRIGERANT SYSTEM PERFORMANCE TEST.) A6E8516W022 End Of Sie EVAPORATOR INSPECTION 1. Remove the A/C unit. (See U15 A/C UNIT REMOVAL/INSTALLATION.) 2. Remove the evaporator from the A/C unit. 3. Inspect for cracks, damage, and oil leakage. • If any problems are found, replace the evaporator. 4.
BASIC SYSTEM HEATER CORE INSPECTION 1. Remove the A/C unit. (See U15 A/C UNIT REMOVAL/INSTALLATION.) 2. Remove the heater core from the A/C unit. 3. Inspect for cracks, damage, and coolant leakage. • If any problems are found, replace the heater core. 4. Inspect for bent fins. • If any are bent, use a flathead screwdriver to straighten them. 5. Verify that the heater core inlet and outlet pipe are not distorted or damaged. • Repair with pliers if necessary.
BASIC SYSTEM A/C Compressor Installation Note 1. Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C compressor. Compressor oil to be removed (approximate quantity) 120 ml {120 cc, 4.06 fl oz} [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz}] End Of Sie CONDENSER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (See U9 RECOVERY.) (See U9 CHARGING.) 3. Remove the shroud panel.
BASIC SYSTEM REFRIGERANT LINES REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. A6E851661460W01 Remove the battery. Discharge the refrigerant from the system. (See U9 RECOVERY.) (See U9 CHARGING.) Remove the washer tank. (L.H.D. only) (See T58 WASHER TANK REMOVAL/INSTALLATION.) Remove the air cleaner cover, air cleaner element and air cleaner case. (See F10 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) Remove the charcoal canister. Remove the No.3 engine mount. (L.H.D. only) Remove the shroud panel.
BASIC SYSTEM 12. Perform the refrigerant system performance test. (See U13 REFRIGERANT SYSTEM PERFORMANCE TEST.) .
BASIC SYSTEM U A6E8516W030 1 2 3 Cooler pipe No.1 (See U28 Refrigerant Lines Removal Note) (See U29 Refrigerant Lines Installation Note) Cooler pipe No.2 (See U28 Refrigerant Lines Removal Note) (See U29 Refrigerant Lines Installation Note) Cooler pipe No.3 (See U28 Refrigerant Lines Removal Note) (See U29 Refrigerant Lines Installation Note) 4 5 6 Cooler pipe No.
BASIC SYSTEM Refrigerant Lines Removal Note Nut joint type 1. Loosen the nut using two spanners, then remove the cooler pipe or hose. Block joint type 1. Disconnect the block joint type pipes by grasping female side of the block with pliers or similar tool and holding firmly, then remove the connection bolt or nut. A6E8516W023 Spring-lock coupling type 1. Set the SST. A6E8516W014 2.
BASIC SYSTEM Refrigerant Lines Installation Note 1. When installing a new cooler pipe No.4 or cooler hose (LO), add a supplemental amount of ATMOS GU10 compressor oil into the refrigeration cycle. Supplemental amount (approximate quantity) 5 ml {5 cc, 0.2 fl oz}: Cooler pipe No.4 10 ml {10 cc, 0.3 fl oz}: Cooler hose (LO) 2. Apply compressor oil to the O-rings and connect the joints. 3. Tighten the joints. Nut or block joint type 1. Tighten the nut or bolt of joint by hand. 2.
CONTROL SYSTEM CONTROL SYSTEM AIR INTAKE ACTUATOR REMOVAL/INSTALLATION 1. 2. 3. 4. 1 2 A6E854061060W01 Disconnect the negative battery cable. Remove the glove compartment. Remove the car navigation unit. (See T98 CAR-NAVIGATION UNIT REMOVAL/INSTALLATION.) Remove in the order indicated in the table. Air intake actuator connector Air intake actuator 5. Install in the reverse order of removal. A6E8540W001 End Of Sie AIR INTAKE ACTUATOR INSPECTION A6E854061060W02 1.
CONTROL SYSTEM A6E8540W043 End Of Sie AIR MIX ACTUATOR REMOVAL/INSTALLATION 1. 2. 3. 4. 1 2 A6E854061415W01 Disconnect the negative battery cable. Remove the glove compartment. Remove the car navigation unit. (See T98 CAR-NAVIGATION UNIT REMOVAL/INSTALLATION.) Remove in the order indicated in the table. Air mix actuator connector Air mix actuator 5. Install in the reverse order of removal.
CONTROL SYSTEM AIR MIX ACTUATOR INSPECTION A6E854061415W02 1. Connect battery positive voltage to terminal D or F and ground to terminal F or D of the air mix actuator. 2. Verify that the air mix actuator operates as shown below. • If not as specified, replace the air mix actuator. Connection B+ GND D F F D Movement COLD→HOT HOT→COLD A6E8540W005 A6E8540W006 A6E8540W044 3. Verify that the resistance between the terminals of the air mix actuator are as shown in the graph.
CONTROL SYSTEM AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION 1. 2. 3. 4. 1 2 A6E854061070W01 Disconnect the negative battery cable. Remove the glove compartment. Remove the car navigation unit. (See T98 CAR-NAVIGATION UNIT REMOVAL/INSTALLATION.) Remove in the order indicated in the table. Airflow mode actuator connector Airflow mode actuator 5. Install in the reverse order of removal.
CONTROL SYSTEM AIRFLOW MODE ACTUATOR INSPECTION A6E854061070W02 1. Connect battery positive voltage to terminal D or F and ground to terminal F or D of the airflow mode actuator. 2. Verify that the airflow mode actuator operates as shown below. • If not as specified, replace the airflow mode actuator. Connection B+ GND D F F D Movement DEFROSTER → VENT VENT → DEFROSTER A6E8540W008 A6E8540W009 A6E8540W046 3.
CONTROL SYSTEM BLOWER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 1 2 A6E854061140W01 Blower motor connector Blower motor 3. Install in the reverse order of removal. A6E8540W060 End Of Sie BLOWER MOTOR INSPECTION A6E854061140W02 1. Connect battery positive voltage to terminal A and ground to terminal B of the blower motor and verify its operation. • If not as specified, replace the blower motor.
CONTROL SYSTEM RESISTOR INSPECTION 1. Verify that the resistance between the terminals of the resistor is as shown in the table. • If not as specified, replace the resistor. Terminal AD AB AC A6E854061215W02 Resistance (ohm) 0.210.23 0.600.68 2.292.62 A6E8540W012 End Of Sie POWER MOS FET REMOVAL/INSTALLATION (See U35 RESISTOR REMOVAL/INSTALLATION.) A6E854061B15W01 End Of Sie POWER MOS FET INSPECTION 1.
CONTROL SYSTEM Bolt Removal/Installation Note 1. When removing or installing the bolt, hold the pressure plate in place as shown in the figure. 2. When installing a new A/C compressor body, replace the bolt. A6E8540W048 Stator and Thermal Protector Removal Note 1. After removing the stator and thermal protector, completely remove the silicone adhering to the A/C compressor side. Stator and Thermal Protector Installation Note 1. Apply approximately 1 g {0.
CONTROL SYSTEM MAGNETIC CLUTCH ADJUSTMENT 1. Measure the clearance around the entire circumference between the pressure plate and A/ C compressor pulley using a thickness gauge. 2. Verify that the clearance is within the specification. • If not within the specification, remove the pressure plate and adjust the clearance by changing the shim (0.2 mm {0.008 in}, 0.5 mm {0.02 in}) or the number of shims. Clearance 0.30.5 mm {0.0120.
CONTROL SYSTEM SOLAR RADIATION SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the solar radiation sensor from the dashboard using a tape-wrapped flathead screwdriver. 3. Install in the reverse order of removal. A6E854061751W01 A6E8540W017 End Of Sie SOLAR RADIATION SENSOR INSPECTION A6E854061751W02 1. Shine an incandescent light (60 W) on the solar radiation sensor from a distance of approximately 100 mm {3.94 in}. 2.
CONTROL SYSTEM AMBIENT TEMPERATURE SENSOR INSPECTION End Of Sie 1. Measure the temperature around the ambient temperature sensor. 2. Measure the resistance between terminals of the ambient temperature sensor. • If the resistance is not as shown in the graph, replace the ambient temperature sensor. A6E8540W019 End Of Sie CABIN TEMPERATURE SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the lower panel. (See S84 LOWER PANEL REMOVAL/INSTALLATION.) 3.
CONTROL SYSTEM CABIN TEMPERATURE SENSOR INSPECTION 1. Measure the temperature around the cabin temperature sensor. 2. Measure the resistance between terminals of the cabin temperature sensor. • If the resistance is not as shown in the graph, replace the cabin temperature sensor. A6E854061757W02 A6E8540W021 End Of Sie EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION A6E854061022W01 1. Remove the evaporator temperature sensor from the A/C unit. (See U18 A/C UNIT DISASSEMBLY/ ASSEMBLY.
CONTROL SYSTEM WATER TEMPERATURE SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the dashboard. (See S82 DASHBOARD REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 1 2 3 4 A6E854061752W01 Air hose Duct (3) Plate spring Water temperature sensor 4. Install in the reverse order of removal. A6E8540W023 End Of Sie WATER TEMPERATURE SENSOR INSPECTION 1. Measure the temperature around the water temperature sensor. 2.
CONTROL SYSTEM REFRIGERANT PRESSURE SWITCH INSPECTION A6E854061503W02 1. Install the SST (gas charging set). 2. Disconnect the refrigerant pressure switch connector. 3. Verify the high-pressure side reading of the SST (manifold gauge) and continuity between the terminals of the refrigerant pressure switch. • If not as specified, replace the refrigerant pressure switch.
CONTROL SYSTEM A6E8540W027 End Of Sie CLIMATE CONTROL UNIT REMOVAL 1. 2. 3. 4. 5. 6. A6E854061190W03 Disconnect the negative battery cable. Disconnect the air mix and airflow mode wires from each wire clamp and link. (Manual air conditioner) Remove the center panel. (See T96 CENTER PANEL MODULE REMOVAL/INSTALLATION.) Remove the screws and climate control unit. (Full-auto air conditioner) Release the hook and pull the climate control unit toward you.
CONTROL SYSTEM CLIMATE CONTROL UNIT INSTALLATION 1. Pass each wire through the following routes then connect to A/C unit. (Manual air conditioner) 2. Connect the climate control unit connectors. (Manual air conditioner) 3. Install the climate control unit to the center panel. (Full-auto air conditioner) 4. Install the center panel. 5. Adjust the climate control unit wires. (Manual air conditioner) (See U46 CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) 6. Connect the negative battery cable.
CONTROL SYSTEM Wire Disassembly Note 1. Disassemble the wires in the shown in the figure. A6E8540W031 Wire Assembly Note 1. Assemble the wires to the position as shown in the figure. A6E8540W032 A6E8540W033 End Of Sie CLIMATE CONTROL UNIT WIRE ADJUSTMENT Air Mix Wire 1. Set the temperature control dial at max cold. 2. Set the air mix link to max cold in the direction shown by the arrow and insert a screwdriver at the set hole. 3. Connect the air mix wire to air mix link. 4.
CONTROL SYSTEM 2. Set the airflow mode main link to defroster in the direction shown by the arrow and insert a screwdriver at the set hole. 3. Connect the airflow mode wire to airflow mode main link. 4. Clamp the airflow mode wire to wire clamp. 5. Verify that the airflow mode control dial moves its full stroke. A6E8540W035 End Of Sie CLIMATE CONTROL UNIT INSPECTION Full-auto Air Conditioner 1. Connect the all center panel connectors. 2. Turn the ignition switch to ON position. 3.
CONTROL SYSTEM Terminal Signal 1C Blower motor control signal 1D 1E Rear window defroster SW signal Connected to Power MOS FET Rear window defroster relay Test condition Fan switch is OFF Fan switch is at manual LO Fan switch is at manual HI Rear window defroster switch is off Voltage (V) Below 1.0 4.1 Action • Inspect terminal voltage of climate control unit (1A) 7.9 • 12 • 1F On-board diagnostic signal A/C check connector Rear window defroster switch is on Below 1.
CONTROL SYSTEM Terminal Signal 1O Water temperature sensor input Connected to Water temperature sensor Test condition Depends on temperature surrounding sensor Voltage (V) See Figure 4 1P A/C Refrigerant pressure switch Fan switch at OFF 12 1Q Evaporator temperature sensor input signal Fan switch at 1st position, A/C switch ON Evaporator Depends on temperature temperature sensor surrounding sensor Below 1.
CONTROL SYSTEM Terminal Signal 1W Potentiometer signal 1X Hazard warning SW signal Connected to Airflow mode actuator Hazard warning switch Test condition VENT mode BI-LEVEL mode HEAT mode HEAT/DEF mode DEFROSTER mode Hazard warning switch is off Hazard warning switch is on 2A 2B Panel light control Panel light control signal switch TNS signal TNS relay Headlight switch ON and panel light control switch at max. illumination Headlight switch ON and panel light control switch at min.
CONTROL SYSTEM Terminal Signal 2H IG2 Connected to A/C 15 A fuse Test condition Ignition switch at ON position Ignition switch at LOCK position 2I 2J 2K 2L Motor drive signal Air intake actuator Motor drive signal Air intake actuator GND Ground Moving to RECIRCULATE Moving to FRESH Moving to FRESH Moving to RECIRCULATE Under any condition Voltage (V) B+ Below 1.0 12 Below 1.0 12 Below 1.0 Below 1.
CONTROL SYSTEM FAN SWITCH INSPECTION 1. Remove the climate control unit. 2. Inspect for continuity between the fan switch terminals using an ohmmeter. • If not as specified, replace the fan switch. End Of Sie A6E8540W056 DEFROSTER SWITCH INSPECTION 1. Remove the climate control unit. 2. Inspect for continuity between the defroster switch terminals using an ohmmeter. • If not as specified, replace the climate control unit.
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC DIAGNOSTIC TROUBLE CODE NUMBER INSPECTION 1. Remove the glove compartment. 2. Short the A/C check connector to the GND terminal using a jumper wire. 3. Shine a 60 W incandescent light from a height of approximately 100 mm {3.9 in} onto the solar radiation sensor. A6E857001038W01 Note • When incandescent light does not shine on the solar radiation sensor, the climate control unit determines a malfunction and indicates a diagnostic trouble code 02. A6E8570W004 4.
ON-BOARD DIAGNOSTIC DTC Table No.
ON-BOARD DIAGNOSTIC Output Device Operation Check Mode Inspection 1. Warm up the engine. 2. Turn the ignition switch to LOCK position. 3. Start up the on-board diagnostic function (present failure indication mode). 4. Press the AUTO switch. 5. Verify that all the indicator lights of the climate control unit and center panel (climate control part) illuminate for 4 seconds. 6.
ON-BOARD DIAGNOSTIC Step Operating device 3 Operating conditions Moni tor* Airflow mode actuator operation 3 4 Air intake actuator operation • Blower motor speed 3rd • Air mix actuator operation 50% • Air intake actuator operation FRESH • A/C compressor operation ON • Blower motor speed 3rd • Air mix actuator operation 0% • Airflow mode actuator operation VENT 4 A/C compressor operation * Other device conditions : Shown on the information display according to step.
ON-BOARD DIAGNOSTIC Diagnostic Procedure STEP 1 2 INSPECTION • Is resistance between terminals 1I and 1M of climate control unit connector (24-pin) as indicated below? 137 ohms220 kilohms • Inspect cabin temperature sensor. • Is it okay? Yes No ACTION Replace climate control unit. Go to next step. Yes No Repair wiring harness. Replace cabin temperature sensor.
ON-BOARD DIAGNOSTIC Diagnostic Procedure STEP 1 2 INSPECTION • Inspect evaporator temperature sensor. • Is it okay? • Disconnect climate control unit connector (24-pin) and evaporator temperature sensor connector.
ON-BOARD DIAGNOSTIC STEP 4 INSPECTION • Turn ignition switch to ON position. • Measure voltage at terminal 1K of climate control unit connector (24-pin). • Is voltage approximately 5 V? Yes No ACTION This system is normal at present. (Erase the past failure from memory.) Replace climate control unit.
ON-BOARD DIAGNOSTIC STEP 2 3 4 INSPECTION • Disconnect airflow mode actuator connector. • Is resistance between terminals 1U and 1I of climate control unit connector (24-pin) more than 387 ohms? • Disconnect climate control unit connector (24-pin). • Is resistance between terminals 1B and 1I of climate control unit connector (24-pin) less than 4.8 kilohms? • Is resistance between terminals 1B and 1U of climate control unit connector (24-pin) less than 4.2 kilohms? Yes No ACTION Go to next step.
ON-BOARD DIAGNOSTIC DTC 22 A6E857001038W14 DTC 22 POSSIBLE CAUSE Airflow mode actuator (potentiometer) system inspection • Airflow mode actuator malfunction • Climate control unit malfunction • Open circuit between airflow mode actuator and climate control unit • Short circuit between airflow mode actuator (terminal C) and climate control unit (terminal 1W: 24-pin) Diagnostic Procedure STEP 1 2 INSPECTION • Inspect airflow mode actuator.
ON-BOARD DIAGNOSTIC Diagnostic Procedure STEP 1 2 3 INSPECTION • Disconnect airflow mode actuator connector. • Connect battery positive voltage to terminal D (or terminal F) and ground to terminal F (or terminal D) of airflow mode actuator connector. • Does airflow mode actuator operate? • Remove airflow mode actuator. • Operate airflow mode main link by hand. • Does airflow mode main link operate smoothly? • Disconnect climate control unit connect (12pin).
ON-BOARD DIAGNOSTIC Diagnostic Procedure STEP 1 INSPECTION • Disconnect climate control unit connector (24-pin) and evaporator temperature sensor connector. • Is there continuity between terminal 1I of climate control unit connector (24-pin) and terminal A of evaporator temperature sensor connector? Yes No ACTION Replace climate control unit. Repair wiring harness.
TROUBLESHOOTING TROUBLESHOOTING FOREWORD A6E858001038W01 • The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to verify the symptoms of the trouble in order to diagnose the appropriate area. End Of Sie TROUBLESHOOTING INDEX No. 1 2 4 TROUBLESHOOTING ITEM Insufficient air (or no air) blown from vents. Amount of air blown from vents does not change. (Fullauto air conditioner) Amount of air blown from vents does not change.
TROUBLESHOOTING NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM VENTS 1 DESCRIPTION POSSIBLE CAUSE A6E858001038W03 Insufficient air (or no air) blown from vents. • Problem with each vent and/or duct.
TROUBLESHOOTING STEP INSPECTION 4* INSPECT TO SEE WHETHER MALFUNCTION IS IN BLOWER RELAY SYSTEM OR POWER MOS FET SYSTEM • Turn ignition switch to ON position. • Test voltage at the following terminal of blower motor. Terminal B (blower motor operation signal) • Is voltage approximately 12 V? 5* INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY BETWEEN FUSE BLOCK AND BLOWER RELAY) OR ELSEWHERE • Test voltage at the following terminal of blower relay.
ON-BOARD DIAGNOSTIC, TROUBLESHOOTING STEP INSPECTION 12* INSPECT TO SEE WHETHER MALFUNCTION IS IN POWER MOS FET OR ELSEWHERE • Disconnect power MOS FET connector. • Test voltage at the following terminal of power MOS FET. Terminal B (blower motor control signal) • Is voltage approximately 10 V? 13* INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY BETWEEN POWER MOS FET AND CLIMATE CONTROL UNIT) OR ELSEWHERE • Turn ignition switch to LOCK position.
TROUBLESHOOTING STEP INSPECTION 3 INSPECT BLOWER UNIT • Inspect fan in blower unit. Is fan free of interference from blower unit case? Is fan free of foreign material and obstructions? • Is fan okay? 4 INSPECT BLOWER UNIT INTAKE VENT • Is blower unit intake vent clogged? 5 VERIFY THAT MALFUNCTION SYMPTOM OCCURS AFTER REPAIR • Does air blow out? Yes No Yes No Yes No ACTION Go to next step. Remove obstruction, repair or replace fan and blower unit case, then go to Step 5.
TROUBLESHOOTING STEP INSPECTION 3 INSPECT TO SEE WHETHER MALFUNCTION IS IN AIR INTAKE ACTUATOR OR ELSEWHERE • Disconnect air intake actuator connector. • Test voltages at the following terminals of climate control unit.
TROUBLESHOOTING NO.5 NO TEMPERATURE CONTROL WITH CLIMATE CONTROL UNIT 5 DESCRIPTION POSSIBLE CAUSE A6E858001038W07 No temperature control with climate control unit. • Malfunction in A/C unit and/or climate control unit air mix system.
TROUBLESHOOTING POSSIBLE CAUSE • • • • Climate control unit (B+ signal) system malfunction (Steps 2, 4, 5) Air intake actuator malfunction (Steps 3, 7) Climate control unit (RECIRCULATE, FRESH signal) system malfunction (Steps 911) Malfunction in blower unit air intake doors (Steps 12, 13) Diagnostic procedure STEP INSPECTION 1 COOL AIR BLOW OUT INSPECTION • When both A/C and fan switch in climate control unit are on, does cool air blow out from front vent? 2 INSPECT CLIMATE CONTROL UNIT POWER SUPPLY FU
TROUBLESHOOTING STEP INSPECTION *9 INSPECT WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR FOR CONTINUITY • Turn ignition switch to LOCK position.
TROUBLESHOOTING STEP INSPECTION 3 CHECK TO SEE WHETHER MALFUNCTION IS IN BLOWER UNIT INTAKE AND CONDENSER OR ELSEWHERE • Are refrigerant high-pressure and lowpressure values both high? 4 INSPECT BLOWER UNIT INTAKE • Is blower unit intake clogged? 5 6 7 8 9 10 11 INSPECT CONDENSER • Inspect condenser.
TROUBLESHOOTING STEP INSPECTION 12 INSPECT EVAPORATOR PIPING CONNECTIONS IN A/C UNIT FOR LOOSE • Are piping connections for evaporator in A/C unit loose? 13 INSPECT PIPING CONNECTIONS FOR LOOSE • Are piping connections loose? Yes No ACTION Tighten connections with specified torque, adjust both compressor oil and refrigerant to specified amount, then go to Step 20. If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil to the A/C compressor. Verify that the noise is no longer heard.
TROUBLESHOOTING NO.8 NO COOL AIR End Of Sie 8 DESCRIPTION POSSIBLE CAUSE A6E858001038W10 No cool air • Magnetic clutch does not operate.
TROUBLESHOOTING STEP INSPECTION 9 INSPECT TO SEE WHETHER MALFUNCTION IS IN REFRIGERANT PRESSURE SWITCH OR REFRIGERANT AMOUNT • Inspect refrigerant pressure switch.
TROUBLESHOOTING Diagnostic procedure STEP INSPECTION 1 CHECK A/C COMPRESSOR VANE NOISE • Is there a jingling, popping, beeping, or buzzing sound (A/C compressor vane noise)? 2 INSPECT A/C COMPRESSOR SLIPPAGE NOISE • Is there a squeaking or whirling sound (A/C compressor slippage noise)? 3 INSPECT A/C COMPRESSOR INTERFERENCE NOISE • Is there a rattling or vibrating sound (interference noise)? 4 INSPECT MAGNETIC CLUTCH OPERATION NOISE • Is there a clicking sound (magnetic clutch operation noise)? ACTION Yes
TROUBLESHOOTING STEP INSPECTION 13 INSPECT A/C COMPRESSOR OIL • Is compressor oil darker than normal and contaminated with aluminum chips? 14 15 16 17 18 19 * CHECK TO SEE WHETHER MALFUNCTION IS IN A/C COMPRESSOR OR ELSEWHERE • Is noise heard immediately after A/C compressor is stopped? INSPECT DRIVE BELT • Inspect drive belt.
TECHNICAL DATA T D TECHNICAL DATA ............................................. TD-2 ENGINE ............................................................ TD-2 LUBRICATION SYSTEM .................................. TD-2 COOLING SYSTEM.......................................... TD-3 FUEL AND EMISSION CONTROL SYSTEMS . TD-3 ENGINE ELECTRICAL SYSTEM ..................... TD-4 CLUTCH............................................................ TD-5 MANUAL TRANSAXLE.....................................
TECHNICAL DATA TECHNICAL DATA ENGINE A6E931001001W01 Item Engine LF L8 L3 MECHANICAL (mm {in} IN [Engine cold]) EX valve clearance 0.220.28 {0.00870.0110} 0.270.33 {0.01060.0130} 1,750 {17.8, 253} 1,720 {17.5, 249} 1,430 {14.6, 208} [300 rpm] [300 rpm] [290 rpm] 1,225 1,204 1,000 {12.492, 177.64} {12.277, 174.58} {10.197, 145.
TECHNICAL DATA COOLING SYSTEM A6E931001001W03 Item Engine LF 7.5 {7.9, 6.6} L8 Coolant capacity (L {US qt, Imp qt}) Cap valve opening pressure Radiator cap (kPa {kgf/cm2, psi}) Type Initial-opening temperature Thermostat Full-opening temperature Full-open lift 113142 {1.151.44, 16.420.6} Wax, bottom-bypass (°C {°F}) (°C {°F}) 8084 {176183} 90{194} 8.0{0.32} min. (mm {in}) Type Cooling fan Blade L3 Cooling fan No.1: 5, Cooling fan No.
TECHNICAL DATA ENGINE ELECTRICAL SYSTEM A6E931001001W05 Item Engine LF 1.271.29 L8 Electrolyte gravity Back-up current*1 Market (mA) European spec.
TECHNICAL DATA CLUTCH A6E931001024W01 Item Height (with carpet) Clutch pedal Free play Disengagement point Clutch cover Clutch disc Flywheel mm {in} mm {in} Specification L.H.D.: 226222 {8.508.74} R.H.D.: 229235 {9.029.25} 1.03.0 {0.040.11} 0.10.5 {0.0040.02} (Reference value) 20 {0.79} (Reference value) 130.7 {5.15} (Reference value) 0.6 {0.024} 0.6 {0.024} mm {in} 0.5 {0.020} mm {in} mm {in} mm {in} 0.3 {0.012} 0.7 {0.028} 0.1 {0.
TECHNICAL DATA Item Input/turbine speed sensor ATF temperature: 40160 °C {40 (ohm) 320 °F} Vehicle speedometer sensor (VSS) (V) Shift solenoid A Shift solenoid B ATF Shift solenoid C temperature: Solenoid valve (ohm) 40150 °C Shift solenoid D {40302 °F} Shift solenoid E Pressure control Specification 250600 4.55.5 1.04.2 1.04.2 1.04.2 10.926.2 10.926.2 2.47.
TECHNICAL DATA BRAKING SYSTEM A6E931001020W01 Item CONVENTIONAL BRAKE SYSTEM Brake pedal height Brake pedal Power brake unit Specification (mm {in}) Brake pedal play (mm {in}) Pedal-to-floor clearance (Brake pedal when (mm {in}) depressed at 588 N {60 kgf, 132 lbf}) Fluid pressure when pedal At 0 kPa {0 depressed at mmHg, 0 inHg} 200 N {20 kgf, 44 lbf} (kPa {kgf/cm2, psi}) At 66.7 kPa {500 mmHg, 19.
TECHNICAL DATA SUSPENSION A6E931001013W01 Suspension Item Maximum steering angle Total toe-in Front wheel alignment (Unloaded)*1 Caster angle*2 (Reference value) Camber angle*2 Inner Outer (mm {in}) (degree) normal height up*3 normal height up*3 Steering axis inclination normal (Reference value) height up*3 (mm {in}) Total toe-in (degree) Rear wheel normal alignment Camber angle*2 (Unloaded)*1 height up*3 Thrust angle Front upper arm Ball joint rotation (N·m {kgf·cm, Front lower arm (front) torque in·l
TECHNICAL DATA Wheel and Tires Item Standard tire and wheel Size Offset Wheel Pitch circle diameter Material Size Tire Wheel and tire (mm {in}) (mm {in}) 15 × 6JJ 50 {1.97} Steel 195/65R15 91V Up to 4 persons Full load Up to 4 persons Rear Full load Remaining tread (mm {in}) Wheel and tire runout Radial direction (mm {in}) Lateral direction 2.5 {0.10} max.
TECHNICAL DATA BODY ELECTRICAL SYSTEM A6E931001047W01 Item Low beam Headlight Halogen type Discharge type High beam Exterior light bulb capacity (W) Parking light Front fog light Front turn light Front side turn light Brake light/taillight Rear turn light Back-up light Rear fog light License plate light High-mount brake light Interior light bulb capacity (W) 4SD In-vehicle-type Rear spoiler type Specifications 55 × 2 35 × 2 55 × 2 5×2 55 × 2 21 × 2 5×2 21/5 × 2 21 × 2 18.4 × 2 21 × 1 5×2 18.
SPECIAL TOOLS S T SPECIAL TOOLS .................................................ST-2 ENGINE .............................................................ST-2 LUBRICATION SYSTEM ...................................ST-2 COOLING SYSTEM...........................................ST-2 FUEL AND EMISSION CONTROL SYSTEMS ..ST-3 CLUTCH.............................................................ST-3 MANUAL TRANSAXLE......................................ST-3 AUTOMATIC TRANSAXLE................................
SPECIAL TOOLS SPECIAL TOOLS ENGINE A6E941001001W01 Ford SST numbers are collated with Mazda SST numbers in the example below. Ford SSTs are marked with Ford SST number.
SPECIAL TOOLS End OfAND SieEMISSION CONTROL SYSTEMS FUEL A6E941001001W04 49 B019 901B 49 N013 101A 49 N013 102A Oil Pressure Gauge Body Adapter Hose 49 L018 001 49 T042 001 WDS O2 sensor wrench Union wrench End Of Sie CLUTCH A6E941001024W01 49 0259 770B 49 SE01 310A 49 E011 1A0 Flare Nut Wrench Clutch Disc Centering Tool Ring Gear Brake Set End Of Sie MANUAL TRANSAXLE A6E941001024W02 49 G030 795 49 E017 5A0 Oil Seal Installer Engine Support Set ST End Of Sie ST3
SPECIAL TOOLS AUTOMATIC TRANSAXLE A6E941001024W03 49 H019 002 49 0378 400C 49 B019 901B Adapter Oil Pressure Gauge Set Oil Pressure Gauge 49 G030 795 Oil Seal Installer 49 E017 5A0 WDS Engine Support Set 49 E011 1A0 Ring Gear Brake Set End Of Sie FRONT AND REAR AXLE A6E941001018W01 49 0259 770B 49 T028 3A0 49 G030 455 Flare Nut Wrench Ball joint puller set Diff.
SPECIAL TOOLS 49 G026 105 49 H027 002 49 W034 301 Sensor rotor installer Bearing remover Support block 49 S231 626 49 B014 001 49 B025 004 Support block Oil seal installer Dust seal installer 49 F027 005 49 W027 003 49 T025 001 Attachment ø62 Bearing installer Boot clamp crimper End Of Sie ST ST5
SPECIAL TOOLS STEERING SYSTEM A6E941001034W01 49 1232 670B 49 H002 671 49 G032 3A4 Power steering gauge set Adapter Power steering gauge adapter set 49 T028 3A0 49 B032 320 49 B032 317 Ball joint puller set Wrench Bearing and oil seal remover 49 F032 303 49 B032 323 49 N032 319A Handle Rod seal remover body Support plate 49 B032 326 49 T028 301 49 B032 324 Outer box protector Support plate Rod seal protector body 49 B032 325 49 B032 331 49 B001 797 Rod seal guide Oil seal insta
SPECIAL TOOLS End Of SieSYSTEM BRAKING A6E941001020W01 49 0259 770B 49 G066 001 49 U043 0A0A Flare nut wrench Adapter harness Oil pressure gauge set 49 C066 001 49 0221 600C 49 FA18 602 Adapter harness Disc brake expand tool Disc brake piston wrench 49 G043 001 49 E043 003A 49 B043 004 Adjust gauge Turning lock tool Socket wrench 49 0208 701A WDS Boot air out tool End Of Sie ST ST7
SPECIAL TOOLS SUSPENSION A6E941001013W01 49 T034 1A0 49 T034 101 49 T034 105 Coil spring compressor set Coil spring compressor Attachment 49 0107 680A 49 T028 3A0 49 T034 202A Engine stand Ball joint puller set Guide 49 B034 216 49 S120 620 49 T034 203 Installer Bearing installer Attachment 49 G030 797 49 U034 204 49 U027 005 Handle Dust boot installer Bearing installer 49 G026 103 49 E017 5A0 49 G033 102 Support block Engine support set Handle 49 G033 106 49 W034 308 49 80
SPECIAL TOOLS BODY ELECTRICAL SYSTEM 49 H066 002 Deployment tool 49 L066 002 Adapter harness A6E941001047W02 49 D066 002 Adapter harness 49 G066 003 Adapter harness 49 N088 0A0 Fuel and Thermometer checker WDS End Of Sie HEATER AND AIR CONDITIONER SYSTEMS A6E941001038W01 49 C061 0A0B 49 C061 012 49 C061 013 Gas Charge Set Anti-Back Flow Valve Gas Leak Tester 49 G061 001 Spring lock coupling disconnect tool End Of Sie ST9
