Honda 2004 Odyssey Service Manual Download Page 857

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Ｓ０Ｘ４ＡＡ１０００００００Ｊ１４０３ＺＣＡＴ００

5-speed
Automatic Transmission
(2002-2004 Models)

Automatic Transmission

A/T Gear Position Indicator

A/T Interlock System

Transmission End Cover

Transmission Housing

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Special Tools

. 14-246

General Troubleshooting Information

. 14-247

DTC Troubleshooting Index

.14-251

Symptom Troubleshooting Index

. 14-252

System Description

. 14-262

DTC Troubleshooting

. 14-316

Road Test

. 14-352

Stall Speed Test

. 14-354

Pressure Test

. 14-355

Torque Converter Clutch Solenoid Valve

Test

. 14-357

Torque Converter Clutch Solenoid Valve

Replacement

. 14-357

Shift Solenoid Valve A Test

. 14-359

Shift Solenoid Valve A Replacement

. 14-359

Shift Solenoid Valve B Test

. 14-358

Shift Solenoid Valve B Replacement

. 14-358

Shift Solenoid Valve C Test

. 14-359

Shift Solenoid Valve C Replacement

. 14-359

A/T Clutch Pressure Control Solenoid Valve

Solenoid Valve A Test

. 14-360

Solenoid Valve A Replacement

. 14-361

Solenoid Valve B Test

. 14-360

Solenoid Valve B Replacement

. 14-361

Solenoid Valve C Test

. 14-362

Solenoid Valve C Replacement

. 14-363

Input Shaft (Mainshaft) Speed Sensor

Replacement

. 14-364

Output Shaft (Countershaft) Speed Sensor

Replacement

. 14-364

3rd Clutch Transmission Fluid

Pressure Switch Replacement

. 14-365

4th Clutch Transmission Fluid

Pressure Switch Replacement

. 14-365

ATF Temperature Sensor Replacement

. 14-366

ATF Level Check

. 14-367

ATF Replacement

. 14-368

Transmission Removal

. 14-369

Drive Plate Removal and Installation

. 14-378

Transmission Installation

. 14-379

ATF Cooler Flushing

. 14-388

ATF Cooler Hoses Replacement

. 14-389

Shift Lever Removal

. 14-390

Shift Lever Installation

. 14-391

Shift Lever Disassembly/Reassembly

. 14-392

Shift Cable Replacement

. 14-393

Shift Cable Adjustment

. 14-395

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Component Location Index

. 14-397

Circuit Diagram

. 14-398

D Indicator Circuit Troubleshootig

. 14-399

Indicator Input Test

. 14-402

Transmission Range Switch Test

. 14-403

Transmission Range Switch

Replacement

. 14-404

Indicator Bulb Replacement

. 14-406

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Component Location Index

. 14-407

Circuit Diagram

. 14-408

Shift Lock System Circuit

Troubleshooting

. 14-409

Key Interlock System Troubleshooting

. 14-412

Control Unit Input Test

. 14-414

Key Interlock Solenoid/Switch Test

. 14-415

Shift Lock Solenoid Test

. 14-415

Shift Lock Solenoid Replacement

. 14-416

Park Pin Switch Test/Replacement

. 14-417

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End Cover, 3rd Gear, Idler Gear,

and 3rd Clutch Removal

. 14-418

Park Lever Stop

Inspection and Adjustment

. 14-420

Control Shaft Oil Seal Replacement

. 14-421

Control Shaft Bearing Replacement

. 14-421

ATF Feed Pipe Replacement

. 14-422

End Cover, 3rd Gear, Idler Gear,

and 3rd Clutch Installation

. 14-469

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Housing and Shaft Assembly Removal

. 14-423

Bearing Removal and Installation

. 14-425

Shaft Assembly and Housing

Installation

. 14-466

03/07/29 09:35:57 61S0X050_140_0247

Summary of Contents for 2004 Odyssey

Page 1: ...ar Heater A C 21 123 SRS 23 54 Steering 17 4 Multi fuse relay Box 22 78 Power Distribution 22 80 Under dash Fuse Relay Box Driver s 22 76 Under dash Fuse Relay Box Passenger s 22 77 Under hood Fuse Re...

Page 2: ...366 Removal Installation 22 159 342 Description 22 160 Component Location Index 22 157 331 Circuit Diagram 22 158 340 Description 22 332 Component Location Index 21 64 Description 21 73 Circuit Diagr...

Page 3: ...lter DVD Player Unit D Replacement 7 9 Inspection 7 6 See first page of this Index Replacement 14 421 Replacement 14 421 Replacement 14 440 Component Location Index 19 2 3 Troubleshooting 19 4 Repair...

Page 4: ...leshooting 4 56 Removal Installation 22 343 Component Location Index 22 138 Circuit Diagram 22 139 Component Location Index 11 258 259 260 Test 11 297 Removal Installation 21 42 Test 21 40 Replacement...

Page 5: ...1 Replacement 20 152 Replacement 20 154 Replacement 20 135 Test 22 286 Test Replacement 22 173 Test 22 174 Component Location Index 22 172 Circuit Diagram 22 173 Replacement 11 181 Replacement 11 181...

Page 6: ...Test 22 250 Input Test Dash Lights Brightness Control 22 154 Entry Light Control System 22 140 Interlock System 14 184 414 Lights Exterior 22 124 Lights on Reminder 22 110 Power Door Locks 22 267 Powe...

Page 7: ...ubleshooting 11 196 197 Replacement 20 55 Replacement 20 56 Test 10 10 Replacement 10 16 Troubleshooting 10 22 23 24 Troubleshooting 21 31 Troubleshooting 21 27 Test 10 10 Test 10 11 Test 10 25 Test 2...

Page 8: ...85 386 Replacement 20 148 Test 22 318 Test 22 319 Test 22 309 Test 22 310 Input Test 22 300 Removal Installation 22 320 Component Location Index 20 38 Replacement 20 49 Test 22 317 Replacement 20 18 T...

Page 9: ...6 33 Replacement 6 33 Disassembly Inspection Reassembly 14 435 Description 14 62 309 Test A T Electronic Control System 14 130 357 Torque Converter 14 127 354 Replacement A T Electronic Control System...

Page 10: ...4 4th Clutch Transmission Fluid Pressure Switch 4th 5th Clutch Assembly Service Manual Index cont d Replacement 14 365 Inspection 14 442...

Page 11: ...e whether or not you should perform a given task Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment Wh...

Page 12: ...important safety information in a variety of forms including on the vehicle preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL...

Page 13: ...ncorrect removal and installation of the SRS could lead to personal injury caused by unintentional deployment of the airbags and or side airbags Do not bump the SRS unit Otherwise the system may fail...

Page 14: ...2 Model 1 5 Chassis and Paint Codes 2003 Model 1 6 Chassis and Paint Codes 2004 Model 1 7 Identification Number Locations 1 8 Warning Caution Label Locations 1 9 Under hood Emission Control Label 1 11...

Page 15: ...ntification Number and Federal Motor Vehicle Safety Standard Certification COLOR LABEL 2HJ HONDA OF CANADA MFG HONDA CANADA INC HONDA Light duty truck 2HK HONDA OF CANADA MFG HONDA CANADA INC HONDA Mu...

Page 16: ...and Federal Motor Vehicle Safety Standard Certification COLOR LABEL 2HJ HONDA OF CANADA MFG HONDA CANADA INC HONDA Light duty truck 2HK HONDA OF CANADA MFG HONDA CANADA INC HONDA Multipurpose passenge...

Page 17: ...ral Motor Vehicle Safety Standard Certification COLOR LABEL 2HJ HONDA CANADA INC HONDA Light duty truck 2HK HONDA OF CANADA MFG HONDA CANADA INC HONDA Multipurpose passenger vehicle RL1 ODYSSEY J35A1...

Page 18: ...F CANADA MFG HONDA CANADA INC HONDA Multipurpose passenger vehicle 5FN HONDA MGF OF ALABAMA LLC HONDA Multipurpose passenger vehicle RL1 ODYSSEY J35A4 8 5 door 5 speed Automatic U S model 0 EXL with R...

Page 19: ...le 5FN HONDA MGF OF ALABAMA LLC HONDA Multipurpose passenger vehicle 5FP HONDA MGF OF ALABAMA LLC HONDA Light duty truck RL1 ODYSSEY J35A4 8 5 door 5 speed Automatic U S model 0 EXL with Rear Entertai...

Page 20: ...OF ALABAMA LLC HONDA Multipurpose passenger vehicle HONDA Light duty truck RL1 ODYSSEY J35A4 8 5 door 5 speed Automatic U S model 0 EXL with Rear Entertainment System 5 LX 6 EX 7 EXL with Navigation S...

Page 21: ...ation Identification Number Locations Vehicle Identification Number VIN Vehicle Identification Number VIN Engine Number Transmission Number 5 speed for 2002 2004 models Transmission Number 4 speed for...

Page 22: ...D SEAT SRS WARNING INFORMATION SRS WARNING INFORMATION FRONT PASSENGER MODULE DANGER STEERING COLUMN NOTICE MONITOR NOTICE FRONT SEATBELT TENSIONER CAUTION FRONT PASSENGER AIRBAG WARNING TAG CHILD SEA...

Page 23: ...Under hood Emission Control Label SRS WARNING LABEL AIR CONDITIONING INFORMATION RADIATOR CAP CAUTION BATTERY CAUTION SRS WARNING LABEL ENGINE COOLANT INFORMATION SIDE AIRBAG INFORMATION TIRE INFORMA...

Page 24: ...ters Evaporative Family a Model Year b Manufacturer Subcode c Family Type d Canister Work Capacity e Sequence Characters 1 11 Under hood Emission Control Label HNX X 03 5 T EA3 HNX X 0130 E AAE THIS V...

Page 25: ...ive Family a Model Year b Manufacturer Subcode c Family Type d Canister Work Capacity e Sequence Characters 1 12 General Information Under hood Emission Control Label cont d HNX Y 03 5 T EA3 HNX Y 013...

Page 26: ...Manufacturer Subcode c Family Type d Canister Work Capacity e Sequence Characters 1 13 HNX 1 03 5 T DH2 HNX 1 0160 R AAA THIS VEHICLE CONFORMS TO U S EPA NLEV REGULATIONS APPLICABLE TO 2001 MODEL YEAR...

Page 27: ...U R N E D O F F C O O L I N G F A N O F F 7 1 0 5 0 r p m I D L E S P E E D 3 5 L 3 H N X R 0 1 6 0 A A A M O D E L Y E A R N E W L E V L I G H T D U T Y T R U C K S E P A C E R T I F I C A T I O N T...

Page 28: ...Raise the hoist to full height and inspect the lift points for solid contact with the lift blocks To support the vehicle on safety stands use the same support points B and C as for a frame hoist Alwa...

Page 29: ...main on the ground The tow truck uses metal cables with hooks on the ends These hooks go around parts of the frame or suspension and the cables lift that end of the vehicle off the ground The vehicle...

Page 30: ...have self adhesive labels Replacement body parts have generic self adhesive labels The original engine or transmission VIN plate is transferred to a replacement engine or transmission and attached wi...

Page 31: ...r Exhaust Gas Recirculation Valve Position EGR Valve Position Sensor Exhaust Gas Recirculation Control Solenoid Valve EGR Control Solenoid Valve Exhaust Gas Recirculation Valve Vacuum Control Solenoid...

Page 32: ...Current Sensor Secondary Air Injection Pump Electric Current Sensor Air Pump Electric Current Sensor Shift Clutch Pressure Control Solenoid Valve Set Shift Solenoid and Automatic Transaxle Clutch Pre...

Page 33: ......

Page 34: ...5 speed Automatic Transmission and Differential 2002 2004 Models 2 13 Steering 2 20 Suspension 2 20 Brakes 2 21 Air Conditioning 2 21 Dimensions 2 22 Weight U S A 2 22 Weight CANADA 2 22 Engine 2 22 S...

Page 35: ...5 mm 0 06 in Brush spring tension 3 2 N 0 33 kgf 0 73 lbf Alternator 2002 2004 models Output At 13 5 V and normal engine temperature 130 A Coil rotor resistance At 68 F 20 C 2 3 2 7 k Slip ring O D 1...

Page 36: ...n Exhaust 5 450 5 460 mm 0 2146 0 2150 in 5 420 mm 0 2134 in Stem to guide clearance Intake 0 020 0 045 mm 0 0008 0 0018 in 0 08 mm 0 003 in Exhaust 0 055 0 080 mm 0 0022 0 0031 in 0 12 mm 0 005 in Va...

Page 37: ...0022 in 0 13 mm 0 005 in Ring end gap Top 0 20 0 35 mm 0 008 0 014 in 0 60 mm 0 024 in Second 0 40 0 55 mm 0 016 0 022 in 0 70 mm 0 028 in Oil 0 20 0 70 mm 0 008 0 028 in 0 80 mm 0 031 in Piston pin...

Page 38: ...US qt without rear A C 5 5 5 8 US qt Reservoir Coolant capacity 0 6 0 6 US qt Radiator cap Opening pressure 93 123 kPa 0 95 1 25 kgf cm 14 18 psi Thermostat Opening temperature Begins to open 1999 20...

Page 39: ...0 041 in 3rd 0 55 0 75 mm 0 022 0 030 in 4th 0 55 0 75 mm 0 022 0 030 in Clutch return spring free length 1st 45 7 mm 1 80 in 43 7 mm 1 72 in 2nd 63 0 mm 2 48 in 61 0 mm 2 40 in 3rd 4th 33 5 mm 1 32 i...

Page 40: ...mm 0 5518 0 5525 in When worn or damaged ATF pump driven gear shaft O D 13 980 13 990 mm 0 5504 0 5508 in When worn or damaged Reverse shift fork Fork finger thickness 5 90 6 00 mm 0 232 0 236 in 5 40...

Page 41: ...2 7 90 mm 0 311 in When worn or damaged No 3 7 95 mm 0 313 in When worn or damaged No 4 8 00 mm 0 315 in When worn or damaged No 5 8 05 mm 0 317 in When worn or damaged No 6 8 10 mm 0 319 in When worn...

Page 42: ...th gear 41 000 41 016 mm 1 6142 1 6148 in When worn or damaged I D of idler gear 50 000 50 016 mm 1 9685 1 9691 in When worn or damaged I D of reverse gear 46 000 46 016 mm 1 8110 1 8116 in When worn...

Page 43: ...No 2 4 95 mm 0 195 in When worn or damaged No 3 5 00 mm 0 197 in When worn or damaged No 4 5 05 mm 0 199 in When worn or damaged No 5 5 10 mm 0 201 in When worn or damaged No 6 5 15 mm 0 203 in When w...

Page 44: ...0 579 in 77 4 mm 3 047 in 15 2 Regulator valve spring B 1 6 mm 0 063 in 9 2 mm 0 362 in 44 0 mm 1 732 in 12 5 Lock up control valve spring 0 8 mm 0 031 in 6 6 mm 0 260 in 44 3 mm 1 744 in 25 5 Lock u...

Page 45: ...act area I D 30 025 30 045 mm 1 182 1 183 in Carrier to driveshaft clearance 0 045 0 086 mm 0 002 0 003 in 0 12 mm 0 005 in Carrier to intermediate shaft clearance 0 080 0 116 mm 0 003 0 005 in Tapere...

Page 46: ...kgf cm 120 psi 1st clutch pressure At 2 000 rpm in 1 position 890 970 kPa 9 1 9 9 kgf cm 130 140 psi 840 kPa 8 6 kgf cm 120 psi 1st hold clutch pressure At 2 000 rpm in 1 position 760 830 kPa 7 7 8 5...

Page 47: ...n discolored Mark 4 3 40 mm 0 134 in When discolored Mark 6 2 60 mm 0 102 in When discolored Mark 7 2 70 mm 0 106 in When discolored Mark 8 2 80 mm 0 110 in When discolored Mark 9 2 90 mm 0 114 in Whe...

Page 48: ...13 in When worn or damaged No 4 8 00 mm 0 315 in When worn or damaged No 5 8 05 mm 0 317 in When worn or damaged No 6 8 10 mm 0 319 in When worn or damaged Thrust washer thickness 27 x 47 x 5 mm 5 00...

Page 49: ...10 1 8116 in When worn or damaged End play of 1st gear 0 00 0 33 mm 0 000 0 013 in End play of 5th gear 0 04 0 27 mm 0 002 0 011 in End play of 3rd gear 0 015 0 045 mm 0 0006 0 0018 in End play of rev...

Page 50: ...197 in When worn or damaged No 4 5 05 mm 0 199 in When worn or damaged No 5 5 10 mm 0 201 in When worn or damaged No 6 5 15 mm 0 203 in When worn or damaged No 7 5 20 mm 0 205 in When worn or damaged...

Page 51: ...240 in 17 8 mm 0 701 in 7 9 Regulator valve body spring see page 14 433 Stator reaction spring 5 5 mm 0 217 in 37 4 mm 1 472 in 30 3 mm 1 193 in 2 1 Regulator valve spring A 1 9 mm 0 075 in 14 7 mm 0...

Page 52: ...122 in 19 6 mm 0 772 in 39 4 mm 1 551 in 5 5 A T differential carrier Pinion shaft contact area I D 18 000 18 025 mm 0 7087 0 7096 in Carrier to pinion shaft clearance 0 013 0 054 mm 0 001 0 002 in 0...

Page 53: ...p belt NOTE Adjust a belt to the new belt spec run the engine for 5 minutes then readjust it to the belt spec Deflection with 98 N 10 kgf 22 lbf applied mid way between pulleys Used belt 13 0 16 5 mm...

Page 54: ...4 N 30 kgf 66 lbf of force 4 6 clicks Brake pedal Pedal height carpet removed 164 mm 6 7 16 in Free play 1 5 mm 1 16 3 16 in Brake disc Disc thickness Front 27 9 28 1 mm 1 10 1 11 in 26 0 mm 1 02 in R...

Page 55: ...0 Valve train Belt driven SOHC VTEC 4 valves per cylinder Lubrication system Forced wet sump with trochoid pump Oil pump displacement At 6 000 rpm 58 4 61 7 US qt minute Water pump displacement At 6 0...

Page 56: ...9 sq in x 4 Rear 2002 2004 models 58 cm x 4 9 0 sq in x 4 TIRES Size of front and rear tires 1999 2001 models P215 65R16 96T 2002 2004 models P225 60R16 98T Size of spare tires T135 80D16 101M AIR CON...

Page 57: ...ts high low 12 V 60 55 W Front turn signal Front side marker lights 12 V 21 W 5 W two filaments Rear turn signal lights 12 V 21 W Brake Taillights 12 V 21 5 W Inner Taillights 12 V 5 W High mount brak...

Page 58: ...2 25 Body Specifications VAN LX EX EXL 1 740 mm 68 5 in 1 770 mm 69 7 in 1 680 mm 66 1 in 1 680 mm 66 1 in 1 920 mm 75 6 in 3 000 mm 118 1 in 5 110 mm 201 2 in 1 2 1 2...

Page 59: ......

Page 60: ...Conditions Listed by Distance Time for Nomal Conditions Listed by Distance Time for Severe Conditions Listed by Distance Time for Nomal Conditions Listed by Distance Time for Severe Conditions Lubrica...

Page 61: ...ttle cable end Throttle link Super High Temp Urea Grease P N 08798 9002 7 8 9 10 11 12 13 14 Brake booster clevis Pedal linkage Battery terminals Fuel fill door Hood hinges and hood latch Tailgate hin...

Page 62: ...3 3 NOTE Lubricate all hinges latches and locks once a year In corrosive areas more frequent lubrication is necessary We recommend Honda White Lithium Grease...

Page 63: ...00 km 2 years Do items in A B and C 37 500 miles 60 000 km Do items in A 45 000 miles 72 000 km 3 years Do items in A B and D 3 years 52 500 miles 84 000 km Do items in A 60 000 miles 96 000 km 4 year...

Page 64: ...0 miles 24 000 km or 1 year Check bolts for tightness Inspect driveshaft boots see page 16 3 every 15 000 miles 24 000 km or 1 year Check boots for cracks and boot bands for tightness Inspect brake ho...

Page 65: ...s of soot in the air from industry and diesel powered vehicles Replace the filter whenever airflow from the heating and cooling climate control system is less than normal D Replace engine coolant see...

Page 66: ...000 km Do items in A 37 500 miles 60 000 km Do items in A and B 41 250 miles 66 000 km Do items in A 45 000 miles 72 000 km 3 years Do items in A B C D and F 3 years Replace brake fluid see page 19 9...

Page 67: ...tness Check condition of ball joint boots for deterioration and damage Inspect driveshaft boots see page 16 3 every 7 500 miles 12 000 km or 6 months C Check parking brake adjustment see page 19 7 eve...

Page 68: ...climate control system is less than normal Replace transmission fluid see page 14 137 every 30 000 miles 48 000 km or 2 years Capacity 2 9 3 1 US qt use Honda ATF Z1 F Replace engine coolant see page...

Page 69: ...C 37 500 miles 60 000 km Do items in A 45 000 miles 72 000 km 3 years Do items in A B and D 3 years Replace brake fluid see page 19 9 52 500 miles 84 000 km Do items in A 60 000 miles 96 000 km 4 yea...

Page 70: ...000 miles 24 000 km or 1 year Check bolts for tightness Inspect driveshaft boots see page 16 3 every 15 000 miles 24 000 km or 1 year Check boots for cracks and boot bands for tightness Inspect brake...

Page 71: ...soot in the air from industry and diesel powered vehicles Replace the filter whenever airflow from the heating and cooling climate control system is less than normal D Replace transmission fluid see...

Page 72: ...7 500 miles 60 000 km Do items in A and B 41 250 miles 66 000 km Do items in A 45 000 miles 72 000 km 3 years Do items in A B C and D 3 years Replace brake fluid see page 19 9 48 750 miles 78 000 km D...

Page 73: ...ess Check condition of ball joint boots for deterioration and damage Inspect driveshaft boots see page 16 3 every 7 500 miles 12 000 km or 6 months C Check parking brake adjustment see page 19 7 every...

Page 74: ...oling climate control system is less than normal Replace transmission fluid see page 14 137 every 30 000 miles 48 000 km or 2 years Capacity 2 9 3 1 US qt use Honda ATF Z1 F Replace timing belt see pa...

Page 75: ...and C 37 500 miles 60 000 km Do items in A 45 000 miles 72 000 km 3 years Do items in A B and D 3 years Replace brake fluid see page 19 9 52 500 miles 84 000 km Do items in A 60 000 miles 96 000 km 4...

Page 76: ...htness Check condition of ball joint boots for deterioration and damage Inspect driveshaft boots see page 16 3 every 15 000 miles 24 000 km or 1 year Check boots for cracks and boot bands for tightnes...

Page 77: ...centrations of soot in the air from industry and diesel powered vehicles Replace the filter whenever airflow from the heating and cooling climate control system is less than normal D Replace transmiss...

Page 78: ...n A 37 500 miles 60 000 km Do items in A and B 41 250 miles 66 000 km Do items in A 45 000 miles 72 000 km 3 years Do items in A B and C 3 years Replace brake fluid see page 19 9 48 750 miles 78 000 k...

Page 79: ...oots see page 16 3 every 7 500 miles 12 000 km or 6 months C Replace air cleaner element see page 11 240 every 15 000 miles 24 000 km or 1 year Only in dusty conditions if not use the Nomal Conditions...

Page 80: ...14 368 every 30 000 miles 48 000 km or 2 years Capacity 3 3 3 5 US qt use Honda ATF Z1 E Replace timing belt see page 6 20 and inspect water pump see page 10 12 every 105 000 miles 168 000 km or 7 yea...

Page 81: ...19 9 52 500 miles 84 000 km Do items in A 60 000 miles 96 000 km 4 years Do items in A B and C 67 500 miles 108 000 km Do items in A 75 000 miles 120 000 km 5 years Do items in A B and D 82 500 miles...

Page 82: ...amage and leaks Inspect suspension components see page 18 3 every 15 000 miles 24 000 km or 1 year Check bolts for tightness Inspect driveshaft boots see page 16 3 every 15 000 miles 24 000 km or 1 ye...

Page 83: ...trations of soot in the air from industry and diesel powered vehicles Replace the filter whenever airflow from the heating and cooling climate control system is less than normal D Replace transmission...

Page 84: ...o items in A B and C 18 750 miles 30 000 km Do items in A 22 500 miles 36 000 km Do items in A and B 26 250 miles 42 000 km Do items in A 30 000 miles 48 000 km 2 years Do items in A B C and D 33 750...

Page 85: ...uddy dusty or de iced roads 101 250 miles 162 000 km Do items in A 105 000 miles 168 000 km Inspect idle speed see page 11 201 Idle speed 730 50 rpm in N or P position 105 000 miles 168 000 km 7 years...

Page 86: ...s 24 000 km or 1 year Number of clicks 4 to 6 when parking brake pedal is pressed with 294 N 30 kgf 66 lbf of force Lubricate all hinges locks and latches every 15 000 miles 24 000 km or 1 year With H...

Page 87: ...Replace the filter as often at 15 000 miles 24 000 km intervals if the vehicle is driven mostly in urban areas that have high concentrations of soot in the air from industry and diesel powered vehicle...

Page 88: ...2 Alternator Compressor Belt Inspection 4 26 Alternator Compressor Belt Replacement 4 26 Alternator Replacement 4 27 Auto tensioner Inspection 4 28 Auto tensioner Replacement 4 29 Tensioner Pulley Rep...

Page 89: ...Tool Number Description Qty 4 2 Engine Electrical Special Tools A973X 041 XXXXX Vacuum Pump Gauge 0 30 in Hg 1 07746 0010300 Attachment 42 x 47 mm 1 07749 0010000 Driver 1 03 07 29 09 07 13 61S0X050_0...

Page 90: ...E STARTER CUT RELAY BATTERY STARTER Test 1999 2001 models page 14 173 2002 2004 models page 14 403 Replacement 1999 2001 models page 14 174 2002 2004 models page 14 404 Test page 22 88 Starter Circuit...

Page 91: ...42 50A BATTERY UNDER HOOD FUSE RELAY BOX BLU WHT BLK WHT YEL BLK STARTER S B M SOLENOID BLK YEL WHT BLK Closed P and N position No 13 7 5A BLU ORN G101 ST HOT in START III DRIVER S UNDER DASH FUSE RE...

Page 92: ...III The starting system is OK Go to step 4 4 Check the battery condition Check electrical connections at the battery the negative battery cable to the body engine ground cables and the starter for loo...

Page 93: ...mature winding Excessive drag in engine 8 Check engine speed during cranking Go to step 9 Remove and disassemble the starter and check for the following until you find the cause Excessively worn start...

Page 94: ...10 seconds 3 Connect the battery as shown Be sure to disconnect the starter motor wire from the solenoid If the starter pinion pops out it is working properly 4 Disconnect the battery from the M term...

Page 95: ...cable B from the B terminal on the solenoid then disconnect the BLK WHT wire C from the S terminal 4 Remove the two bolts D holding the starter then remove the starter 5 Install in the reverse order...

Page 96: ...ND COVER BRUSH HOLDER BRUSH ARMATURE HOUSING ARMATURE NUT 9 N m 0 9 kgf m 7 lbf ft VENT TUBE STARTER SOLENOID SOLENOID LEVER GEAR HOUSING OVERRUNNING CLUTCH ASSEMBLY GEAR HOUSING COVER cont d Apply mo...

Page 97: ...rom contact with the permanent magnet If there is wear or damage replace the armature 4 Check the commutator A surface If the surface is dirty or burnt resurface with emery cloth or a lathe within the...

Page 98: ...d D 8 Check for continuity between the segments of the commutator If an open circuit exists between any segments replace the armature 9 Place the armature A on an armature tester B Hold a hacksaw blad...

Page 99: ...easure the brush length If it is not within the service limit replace the brush holder assembly 12 Check that there is no continuity between the brush holder A and brush holder B If there is continuit...

Page 100: ...ach brush and smoothly rotate the armature The contact surface of the brushes will be sanded to the same contour as the commutator 16 Install the starter end cover A to retain the brush holder B 17 Sl...

Page 101: ...4 14 Ignition System Component Location Index IGNITION COIL SPARK PLUG Replacement page 4 17 Inspection page 4 18...

Page 102: ...ICM BLK BLK ICM BLK YEL WHT BLU No 6 No 4 YEL BLK YEL ICM BLK No 3 BLK ICM BLK YEL BLU RED BLK YEL ICM BLK No 2 No 1 BLK ICM BLK YEL YEL GRN BLK YEL BLK YEL IG1 BAT IGNITION SWITCH No 41 120A UNDER HO...

Page 103: ...adjust it if necessary see page 11 201 4 Follow the tester s prompts to get the tester in the SCS mode see the tester operator s manual 5 Connect the timing light to the No 1 ignition coil wire 6 Aim...

Page 104: ...2 kgf m 8 7 lbf ft 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf ft B A 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf ft 1 Remove the intake manifold cover A and ignition coil cover s B 2 Disconnect the ignition coil co...

Page 105: ...t range too hot Insufficient cooling Fouled plug may be caused by Retarded ignition timing Oil in combustion chamber Incorrect spark plug gap Plug heat range too cold Excessive idling low speed runnin...

Page 106: ...LAY BOX Has built in ELECTRICAL LOAD DETECTOR ELD UNIT ALTERNATOR CHARGING SYSTEM INDICATOR In the gauge assembly ALTERNATOR BELT BATTERY Alternator Regulator Test step 1 on page 4 23 Replacement page...

Page 107: ...BLK ALTERNATOR RECTIFIER PCM FR SYSTEM INDICATOR LIGHT BULB No 6 15A PCM BATTERY ELD UNIT BLK YEL WHT RED VOLTAGE REGULATOR L IG C B FIELD WINDING FUSE RELAY BOX DRIVER S BLK G201 UNDER HOOD FUSE REL...

Page 108: ...LK YEL FIELD WINDING B C IG L VOLTAGE REGULATOR FR RECTIFIER ALTERNATOR 1 4W CHARGING BLK PCM SYSTEM INDICATOR LIGHT BULB No 6 15A PCM BATTERY ELD UNIT WHT RED FUSE RELAY DRIVER S BLK G201 UNDER HOOD...

Page 109: ...LU wire is shorted to ground the voltage regulator in the alternator may be damaged Go to step 9 6 Turn the ignition switch OFF 7 Disconnect the alternator 4P connector from the alternator 8 Connect t...

Page 110: ...ove the inductive pick up and zero the ammeter 8 Place the inductive pick up over the B terminal wire of the alternator so that the arrow points away from the alternator 9 Raise the engine speed to 2...

Page 111: ...adlights high beam ON 4 Measure voltage between the alternator 4P connector terminal No 2 and the positive terminal of the battery Go to step 8 Go to step 5 5 Turn the headlight and ignition switch OF...

Page 112: ...om the battery 10 Disconnect the PCM connector C 31P 1999 2000 2002 2004 models or PCM connector B 24P 2001 model from the PCM 11 Check for continuity between the PCM connector terminal C2 1999 2000 2...

Page 113: ...r base If pointer is beyond the indicator rib replace the alternator compressor belt 1 Inspect the belt for cracks and damage If the belt is cracked or damaged replace it 2 Check that the pointer A on...

Page 114: ...positive cable 3 Remove the alternator compressor belt see page 4 26 4 Disconnect the alternator 4P connector A and BLK wire B from the alternator 5 Remove the mounting bolt A and alternator bracket...

Page 115: ...lternator compressor belt see page 4 26 4 Move the auto tensioner back and forth within its limit with the wrench in the direction shown Check that the tensioner moves smoothly and without any abnorma...

Page 116: ...se from the tensioner pulley If you hear abnormal noise replace the auto tensioner 3 Remove the alternator compressor belt see page 4 26 4 Move the auto tensioner back and forth within its limit with...

Page 117: ...Remove the alternator compressor belt see page 4 26 2 Remove the auto tensioner 3 Clean the tensioner and pivot bolt A and clean the threads of the pivot bolt hole B with a tap 4 Install the auto ten...

Page 118: ...1999 2001 models 4 31 Tensioner Pulley Replacement A 38 N m 3 9 kgf m 28 lbf ft B Remove the pulley bolt A left hand threads and replace the tensioner pulley B...

Page 119: ...tor Overhaul SPACER RING REAR BEARING ROTOR BEARING RETAINER FRONT BEARING STATOR DRIVE END HOUSING PULLEY PULLEY LOCKNUT STATOR THROUGH BOLT VOLTAGE REGULATOR DIODE RECTIFIER ASSEMBLY REAR HOUSING BR...

Page 120: ...1 on page 4 22 2 Remove the alternator see page 4 27 3 If the front bearing needs replacing remove the pulley locknut with a 10 mm wrench A and a 22 mm wrench B If necessary use an impact wrench 4 Rem...

Page 121: ...tor Overhaul cont d A B A C A B C 7 Remove the voltage regulator 8 Remove the four screws A then remove the rectifier B and rubber seal C 9 Remove the four flange nuts 10 Remove the four insulators A...

Page 122: ...bearing journal surface in the stator housing for seizure marks If either the rotor or stator housing is damaged replace the alternator If both the rotor and the stator housing are OK go to step 13 13...

Page 123: ...ection between the B terminal A and P terminals B and between the E terminal C and P terminals B of each diode pair All diodes should have continuity in only one direction Because the rectifier diodes...

Page 124: ...is no continuity between each slip ring A and the rotor B and the rotor shaft C If there is no continuity go to step 22 If there is continuity replace the alternator 22 Check that there is continuity...

Page 125: ...ging System Alternator Overhaul cont d REAR BEARING ROTOR BEARING RETAINER FRONT BEARING DRIVE END HOUSING PULLEY PULLEY LOCKNUT REAR HOUSING ASSEMBLY BRUSH HOLDER ASSEMBLY TERMINAL INSULATOR END COVE...

Page 126: ...regulator before you remove them see page 4 22 2 Remove the alternator see page 4 27 3 If the front bearing needs replacing remove the pulley locknut with a 10 mm wrench A and a 22 mm wrench B If nece...

Page 127: ...and or rear bearing go to step 15 Otherwise remove the rotor from the drive end housing 9 Inspect the rotor shaft for galling and inspect the bearing journal surface in the drive end housing for seizu...

Page 128: ...OK go to step 14 14 Check that there is continuity between the slip rings A If there is continuity go to step 15 If there is no continuity replace the rotor assembly 15 Check that there is no continui...

Page 129: ...CRUISE CONTROL ACTUATOR ACTUATOR CABLE TRANSMISSION RANGE SWITCH Test page 4 51 Pedal Height Adjustment page 19 6 Test 1999 2001 models page 4 50 2002 2004 models page 4 50 Replacement 1999 2001 model...

Page 130: ...1 5 BLU RED HORN 5 2 6 7 13 9 11 1 14 3 BLK 10 LT GRN BLU HORN SWITCH 12 BLU WHT 4 BLK YEL PCM No 9 10A YEL BLK YEL BLK G201 1 4 3 8 CRUISE CONTROL MAIN SWITCH 5 4 7 2 2 2002 2004models IG1 HOT in ON...

Page 131: ...ts see page 4 48 Poor ground G501 Open circuit loose or disconnected terminals YEL BLU BLK Cruise speed is noticeably higher or lower than what was set Excessive overshooting or undershooting when try...

Page 132: ...e for free operation Check cruise control actuator Open circuit loose or disconnected terminals LT GRN RED LT GRN BLK Set speed will not resume when RESUME button is pressed with main switch on set sp...

Page 133: ...between the No 8 terminal of the cruise control unit 14P connector and body ground Repair a short in the wire between the PCM connector terminal A5 1999 2000 2002 2004 models or E17 2001 model and cru...

Page 134: ...ds over 25 mph 40 km h with the cruise control set and watch the voltmeter Check for loose connection of the BLU GRN wire between the cruise control unit and the PCM If necessary replace the PCM and r...

Page 135: ...age 20 69 2 Disconnect the 14P connector from the cruise control unit 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corrod...

Page 136: ...testing terminal No 6 there should be no voltage on terminal No 7 Blown No 47 20A fuse in the under hood fuse relay box Faulty horn relay Faulty set resume cancel switch Faulty cable reel An open in t...

Page 137: ...ck for continuity between the terminals in each switch position according to the table If the continuity is not specified replace the illumination bulbs or the switch If OK install the switch 1 Carefu...

Page 138: ...tinuity and it matches the table but switch failure was indicated by the cruise control unit input test check and repair the wire harness on the switch circuit If there is no continuity in one or both...

Page 139: ...t the free play at the throttle linkage see page 4 52 after connecting the actuator cable 1 Check that the actuator cable A moves smoothly with no binding or sticking 2 Start the engine and turn the m...

Page 140: ...3 75 0 5 mm 0 15 0 02 in B A 5 Turn the adjusting nut B until it is 3 75 0 5 mm 0 15 0 02 in away from the bracket C 6 Pull the cable so that the adjusting nut B touches the bracket and tighten the l...

Page 141: ...4 54 Engine Mount Control System Component Location Index POWERTRAIN CONTROL MODULE PCM ENGINE MOUNT CONTROL SOLENOID VALVE FRONT MOUNT Troubleshooting page 4 56...

Page 142: ...1 HOT in ON II and START III PCM GRN WHT CONTROL SOLENOID VALVE ENGINE MOUNT No 6 15A BATTERY BLK YEL FUSE RELAY BOX DRIVER S BLK G101 UNDER HOOD FUSE RELAY BOX WHT UNDER DASH IGNITION SWITCH No 41 12...

Page 143: ...enoid valve 2P connector to the solenoid valve The engine mount control system is OK Go to step 4 4 Shift the transmission to P or N 5 Disconnect the engine mount control solenoid valve 2P connector f...

Page 144: ...om the engine mount control solenoid valve B and connect a vacuum pump gauge to the hose Apply vacuum for 20 seconds Go to step 12 Either the vacuum hose or front engine mount has a vacuum leak Repair...

Page 145: ......

Page 146: ...e Mechanical Engine Assembly Cylinder Head 6 1 Engine Block 7 1 Engine Lubrication 8 1 Intake Manifold and Exhaust System 9 1 Engine Removal 5 2 Engine Installation 5 12 03 07 29 09 09 07 61S0X050_050...

Page 147: ...ther wiring or hoses or interfere with other parts 1 Fix the engine hood in a vertical position by using a support rod as shown 2 Make sure you have the anti theft code for the radio and the navigatio...

Page 148: ...999 2001 models or vacuum hose A 2002 2004 models 6 Remove the vacuum hose s B and breather pipe C then remove the intake air duct D 7 Remove the battery 8 Disconnect the engine wire harness connector...

Page 149: ...C 11 Remove the throttle cable A and cruise control actuator cable B by loosening the locknuts C then slip the cable ends out of the accelerator linkage Take care not to bend the cables when removing...

Page 150: ...hose A 16 Remove the vacuum hose B 1999 2001 models 17 Disconnect the powertrain control module PCM connectors from the PCM 18 Remove the engine wire harness clamps A 19 Loosen the grommet mounting nu...

Page 151: ...see page 4 26 22 Loosen the adjusting nut A and remove the locknut B and mounting bolt C then remove the power steering P S pump belt D and pump without disconnecting the P S hoses 23 Remove the P S h...

Page 152: ...lower arm ball joints see step 15 on page 18 13 35 Remove the driveshafts see page 16 3 Coat all precision finished surfaces with clean engine oil Tie plastic bags over the driveshaft ends 36 Remove t...

Page 153: ...9 Remove the nuts securing the transmission lower front mount and transmission lower rear mount 40 Remove the stiffeners 41 Remove the P S hose clamp mounting bolts A and harness clamp B 42 Remove the...

Page 154: ...ar mount 44 Lower the hoist then remove the upper radiator hose A and lower radiator hose B 45 Remove the water bypass hoses C 99 01 models 46 Remove the heater hoses 47 Remove the ATF cooler hoses th...

Page 155: ...5 10 Engine Assembly Engine Removal cont d 48 Attach the chain hoist to the engine as shown 49 Remove the side engine mount bracket 50 Remove the front mount bracket support nut...

Page 156: ...e A C hoses 56 Check that the engine transmission is completely free of vacuum hoses fuel and coolant hoses and electrical wiring 57 Slowly lower the engine about 150 mm 6 in Check once again that all...

Page 157: ...lbf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft P S PUMP BRACKET FRONT MOUNT BRACKET 10 x 1 25 mm 38 N m 3 9 kgf m 28 lbf ft A C COMPRESSOR BRACKET 10 x 1 25 mm 44 N m 4 5 kgf m 33 lbf ft 10 x 1 25 mm...

Page 158: ...mbly under the vehicle Attach the chain hoist to the engine then lift the engine into position in the vehicle Reinstall the mounting bolts nuts in the sequence given Failure to follow this sequence ma...

Page 159: ...bf ft 10 x 1 25 mm 44 N m 4 5 kgf m 33 lbf ft 5 Install the transmission lower front mount and transmission lower rear mount on the front subframe 6 Install the rear mount on the front subframe 7 Lowe...

Page 160: ...0 mm 12 N m 1 2 kgf m 8 7 lbf ft B 11 Raise the vehicle on the hoist to full height 12 Remove the rope from the steering gearbox and install it on the subframe 13 Tighten the power steering P S hose...

Page 161: ...e in the differential and intermediate shaft 17 Connect the suspension lower arm ball joints see page 18 17 18 Connect the stabilizer links see page 18 20 19 Install exhaust pipe A A use new gaskets B...

Page 162: ...n the hoist 27 Install the upper radiator hose A and lower radiator hose B 28 Install the water bypass hoses C 1999 2001 models 29 Install the heater hoses 30 Install the automatic transmission fluid...

Page 163: ...ternator compressor belt 33 Loosely install the P S pump and P S pump belt 34 Adjust the P S pump belt see step 3 on page 17 12 35 Install the battery cable A on the under hood fuse relay box then ins...

Page 164: ...kgf m 16 lbf ft D A B C 22 N m 2 2 kgf m 16 lbf ft 39 Install the brake booster vacuum hose A 40 Install the vacuum hose B 1999 2001 models 41 Install the fuel feed hose A and fuel return hose B using...

Page 165: ...ontrol actuator cable then adjust it see page 4 52 44 Install the throttle cable then adjust it see page 11 242 45 Install the battery base 46 Install the ground cable A relay box bracket B and attach...

Page 166: ...the shift lever to each gear and verify that the A T gear position indicator follows the transmission range switch 56 Inspect for fuel leaks Turn the ignition switch ON II do not operate the starter s...

Page 167: ......

Page 168: ...l 6 34 Cylinder Head Cover Installation 6 34 Cylinder Head Removal 6 35 Cylinder Head Inspection for Warpage 6 38 Rocker Arm Assembly Removal 6 38 Disassembly Reassembly 6 39 6 41 Camshaft Inspection...

Page 169: ...nt 50 mm Offset 1 07NAJ P07010A Pressure Gauge Adapter 1 07PAD 0010000 Stem Seal Driver 1 07VAJ P8A010A VTEC Air Adapter 1 070AJ 0030100 VTEC Air Stopper 1 1 07406 0070300 A T Low Pressure Gauge W Pan...

Page 170: ...VER CRANKSHAFT PULLEY PULLEY BOLT AUTO TENSIONER IDLER PULLEY BOLT IDLER PULLEY TIMING BELT DRIVE PULLEY CKP SENSOR RUBBER SEAL KEY cont d Inspection page 6 19 Removal page 6 20 Installation page 6 23...

Page 171: ...ont d WASHER RUBBER SEAL OIL CONTROL ORIFICE CYLINDER HEAD BOLT CYLINDER HEAD COVER HEAD COVER GASKET CYLINDER HEAD GASKET DOWEL PINS OIL CONTROL ORIFICE O RING CYLINDER HEAD GASKET CYLINDER HEAD O RI...

Page 172: ...G SPRING RETAINER VALVE KEEPERS O RING INTAKE VALVE LOST MOTION ASSEMBLY HOLLOW DOWEL PINS FRONT BANK SOLID DOWEL PINS REAR BANK HOLLOW DOWEL PINS REAR BANK SOLID DOWEL PINS FRONT BANK Removal page 6...

Page 173: ...road test repeat this test two more times Go to step 5 Intermittent failure system is OK at this time Check for poor connections or loose wires at the VTEC solenoid valve and PCM 5 Turn the ignition...

Page 174: ...VTEC solenoid valve 1P connector and VTEC oil pressure switch 2P connector 16 Connect a tachometer 17 Warm up the engine to normal operating temperature cooling fan comes on 18 Check oil pressure at...

Page 175: ...inal C10 1999 2000 2002 2004 models or A20 2001 model and body ground Go to step 24 Replace the VTEC oil pressure switch 24 Turn the ignition switch OFF 25 Disconnect the battery positive terminal fro...

Page 176: ...nd body ground Repair a short in the wire between the PCM connector terminal B12 1999 2000 2002 2004 models or B2 2001 model and VTEC solenoid valve connector Substitute a known good PCM and recheck s...

Page 177: ...ance between the terminal and body ground 3 If the resistance is within specifications remove the VTEC solenoid valve oil filter assembly A from the oil pump and check the VTEC solenoid valve filter B...

Page 178: ...talls 5 Remove the six ignition coils see page 4 17 6 Remove the six spark plugs 7 Attach the compression gauge to a spark plug hole 8 Connect a tachometer 9 Open the throttle fully then crank the eng...

Page 179: ...sembly and check that the piston in the primary rocker arm moves smoothly If any rocker arm needs replacing replace the primary and secondary rocker arms as an assembly and retest If the secondary roc...

Page 180: ...the intake mid rocker arm A for the No 1 cylinder The mid rocker arm should move independently of the primary rocker arm B and secondary rocker arm C If the intake mid rocker arm does not move remove...

Page 181: ...If the synchronizing pistons A and B do not move after applying air pressure move the primary or secondary rocker arm up and down manually 9 Make sure that the intake primary rocker arm A and intake s...

Page 182: ...ign the pointer A on the front upper cover with the No 1 piston TDC mark B on the front camshaft pulley 3 Select the correct thickness feeler gauge for the valves you re going to check 4 Insert the fe...

Page 183: ...r with the No 2 piston TDC mark B on the front camshaft pulley 10 Check and if necessary adjust the valve clearance on No 2 cylinder 11 Rotate the crankshaft clockwise Align the pointer A on the front...

Page 184: ...lockwise Align the pointer A on the front upper cover with the No 6 piston TDC mark B on the front camshaft pulley 16 Check and if necessary adjust the valve clearance on No 6 cylinder 17 Install the...

Page 185: ...h shield 3 Hold the pulley with holder handle A and holder attachment B 4 Remove the bolt with a heavy duty 19 mm socket C and breaker bar 1 Clean the pulleys A crankshaft B bolt C and 2 245 N m 25 0...

Page 186: ...Remove the intake manifold cover A and ignition coil cover B 2002 2004 models 3 Remove the front upper cover 4 Inspect the timing belt for cracks and oil or coolant soaking Replace the belt if it is o...

Page 187: ...1 piston top dead center TDC mark A on the front camshaft pulley and the pointer B on the front upper cover are aligned 3 Remove the right front tire wheel 4 Remove the splash shield 5 Remove the alt...

Page 188: ...racket 9 Remove the dipstick and tube A discard the O ring B 10 Remove the crankshaft pulley see page 6 18 and the timing belt guide plate 11 Remove the front upper cover A rear upper cover B and lowe...

Page 189: ...Screw in the battery clamp bolt as shown to hold the timing belt adjuster in its current position Tighten it by hand do not use a wrench 14 Remove the engine mount bracket 15 Remove the idler pulley b...

Page 190: ...upper and lower covers 2 Set the timing belt drive pulley to top dead center TDC by aligning the TDC mark A on the tooth of the timing belt drive pulley with the pointer B on the oil pump 3 Set the c...

Page 191: ...at blade screwdriver C into the maintenance hole Place the holder D P N 14540 P8A A01 on the auto tensioner while turning the screwdriver clockwise to compress the bottom 1999 model NOTE Take care not...

Page 192: ...clamp bolt in as shown to hold the timing belt adjuster in its current position Tighten it by hand do not use a wrench 15 Apply liquid thread lock to the idle pulley bolt then loosley install the idl...

Page 193: ...nder Head Timing Belt Installation cont d 10 x 1 25 mm 44 N m 4 5 kgf m 33 lbf ft 17 Tighten the idler pulley bolt 18 Remove the holder pin for 2000 2004 models from the auto tensioner 19 Remove the b...

Page 194: ...ket 21 Install the timing belt guide plate as shown 22 Install the lower cover A front upper cover B and rear upper cover C 23 Install the crankshaft pulley see page 6 18 24 Rotate the crankshaft pull...

Page 195: ...marks are at TDC go to step 27 If the camshaft pulley marks are not at TDC remove the timing belt and repeat steps 2 through 26 27 Install the dipstick and tube A with a new O ring B 28 Install and ad...

Page 196: ...iming belt guide plate and the upper and lower covers 2 Set the timing belt drive pulley to TDC by aligning the TDC mark A on the tooth of the timing belt drive pulley with the pointer B on the oil pu...

Page 197: ...procedure 5 Apply liquid thread lock to the idler pulley bolt then loosely install the idler pulley 6 Install the timing belt in a counterclockwise sequence starting with the drive pulley Take care no...

Page 198: ...stall the crankshaft pulley see page 6 18 13 Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions on the pulleys 14 Turn the crankshaft pulley so its white mark...

Page 199: ...5 kgf m 40 lbf ft 16 Install the dipstick and tube A with a new O ring B 17 Install and adjust the P S pump belt see page 17 12 18 Install the alternator compressor belt see page 4 26 19 Install the...

Page 200: ...Install in the auto tensioner 5 Install the timing belt see page 6 23 1 Remove the timing belt see page 6 20 2 Remove the crankshaft position CKP sensor see page 6 61 3 Remove the timing belt drive pu...

Page 201: ...inder head cover clean the cylinder head contacting surfaces with a shop towel Take care not to damage the spark plug seal when installing the cylinder head cover Visually check the spark plug seals f...

Page 202: ...erfere with other parts 1 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset buttons 2 Disconnect the battery negative terminal 3 Drain the eng...

Page 203: ...erature ECT sensor connector Radiator fan switch A connector Radiator fan switch B connector Coolant temperature gauge sending unit connector 1999 2000 models Crankshaft position CKP sensor connector...

Page 204: ...ve the front and rear exhaust manifolds see page 9 10 20 Remove the water passage 21 Remove the camshaft pulleys A and back cover B 22 Remove the cylinder head covers 23 Remove the cylinder head bolts...

Page 205: ...02 in cylinder head resurfacing is not required If warpage is between 0 05 mm 0 002 in and 0 2 mm 0 008 in resurface the cylinder head Maximum resurface limit is 0 2 mm 0 008 in based on a height of 1...

Page 206: ...ts and rocker arms see page 6 41 Rocker arms must be installed in the same positions if reused When removing or installing the rocker arm assembly do not remove the rocker shaft mounting bolts The bol...

Page 207: ...er Arm and Shaft Disassembly Reassembly cont d INTAKE ROCKER SHAFT INTAKE ROCKER ARM ASSEMBLY SPRING EXHAUST ROCKER ARM B EXHAUST ROCKER ARM A EXHAUST ROCKER SHAFT A B A B Letter B is stamped on rocke...

Page 208: ...e diameter of the shaft at the first rocker location 3 Zero the gauge A to the shaft diameter 4 Measure the inside diameter of the rocker arm and check it for an out of round condition 5 Repeat for al...

Page 209: ...on cont d A B B A 6 Inspect the rocker arm piston A Push them manually If they do not move smoothly replace the rocker arm assembly NOTE Apply new engine oil to the pistons when reassembling When reas...

Page 210: ...ge 6 38 3 Put the rocker shafts on the cylinder head then tighten the bolts to the specified torque 4 Seat the camshaft by pushing it toward the rear of the cylinder head 5 Zero the dial indicator aga...

Page 211: ...t journal 9 Zero the gauge to the journal diameter 10 Clean the camshaft bearing surfaces in the cylinder head Measure the inside diameter of each camshaft bearing surface and check for an out of roun...

Page 212: ...nout of the camshaft is within the service limit replace the cylinder head If the total runout is beyond the service limit replace the camshaft and recheck the oil clearance If the oil clearance is st...

Page 213: ...ilable Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position 1 Remove the cylinder head see page 6 34 2 Using an appropriate sized soc...

Page 214: ...rvice Limit 5 420 mm 0 2134 in D Standard New 1 05 1 35 mm 0 041 0 053 in D Service Limit 0 95 mm 0 037 in Intake Valve Dimensions A Standard New 34 90 35 10 mm 1 374 1 382 in B Standard New 115 70 11...

Page 215: ...its guide about 10 mm 0 39 in then measure the guide to stem clearance with a dial indicator while rocking the stem in the direction of normal thrust wobble method If the measurement exceeds the servi...

Page 216: ...linder head to 300 F 150 C Monitor the temperature with a cooking thermometer Do not get the head hotter than 300 F 150 C excessive heat may loosen the valve seats 5 Working from the camshaft side use...

Page 217: ...d installed height A of the guide B If you have all 12 guides to do you may have to reheat the head 10 Coat both the reamer and the valve guide with cutting oil 11 Rotate the reamer clockwise the full...

Page 218: ...ible burrs caused by the other cutters 6 After resurfacing the seat inspect for even valve seating Apply Prussian Blue compound A to the valve face Insert the valve in its original location in the hea...

Page 219: ...69 in Service Limit 47 73 mm 1 879 in 6 52 Cylinder Head Valve Seat Reconditioning cont d A 8 Insert the intake and exhaust valves in the head and measure the valve stem installed height A 9 If the va...

Page 220: ...own smoothly 3 Install the spring seats on the cylinder head 4 Install the new valve seals A using the valve guide seal installer B NOTE Exhaust valve seals C have a black spring D and intake valve se...

Page 221: ...eal in squarely 2 Tap the oil seal in the cylinder head about 0 5 1 5 mm 0 02 0 06 in from the surface of the cylinder head 3 Insert the camshaft B into the cylinder head then install the camshaft thr...

Page 222: ...Install the back cover A then install the camshaft pulley B Install the cylinder heads in the reverse order of removal 1 Clean the cylinder head and block surfaces 2 Clean and install the oil control...

Page 223: ...Set the timing belt drive pulley to top dead center TDC by aligning the TDC mark A on the tooth of the timing belt drive pulley with the pointer B on the oil pump 6 Clean the camshaft pulleys Set the...

Page 224: ...re to tighten slowly and not to overtighten If a bolt makes any noise while you are torquing it loosen the bolt and retighten it from the first step 9 Install the timing belt see page 6 23 10 Adjust t...

Page 225: ...0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf ft 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf ft A B A 15 Install the fuel rails 16 Install the...

Page 226: ...e manifold see page 9 7 20 Loosely install the power steering P S pump and P S pump belt 21 Adjust the P S pump belt see step 3 on page 17 12 22 Install the alternator see page 4 27 23 Install the alt...

Page 227: ...or fuel leakage at any point in the fuel line 29 Refill the radiator with engine coolant and bleed air from the cooling system with the heater valve open see step 8 on page 10 13 30 Inspect the idle s...

Page 228: ...s see page 6 23 1 Remove the altenator compressor belt see page 4 26 2 Loosen the adjusting nut locknut and mounting bolt then remove the power steering P S pump belt see step 6 on page 6 20 3 Remove...

Page 229: ......

Page 230: ...emoval 7 11 Crankshaft and Piston Removal 7 12 Crankshaft Inspection 7 14 Block and Piston Inspection 7 15 7 17 Piston Pin and Connecting Rod Replacement 7 18 Piston Ring Replacement 7 21 Crankshaft a...

Page 231: ...ef No Tool Number Description Qty 7 2 Engine Block Special Tools 070AD RCA0100 1 070AD RCA0200 1 07749 0010000 1 03 07 29 09 12 48 61S0X050_070_0002 Oil Seal Driver 64 mm Driver Driver Attachment 106...

Page 232: ...BLOCK END COVER WASHER O RING DRIVE PLATE BOLT A T DRIVE PLATE VTEC SOLENOID VALVE FILTER VTEC SOLENOID VALVE O RING DOWEL PIN O RING OIL PUMP OIL SCREEN OIL FILTER ASSEMBLY cont d Removal page 7 11 I...

Page 233: ...Block Component Location Index cont d MAIN BEARING CAPS MAIN BEARINGS CRANKSHAFT THRUST WASHERS DOWEL PIN Oil clearance page 7 7 Selection page 7 7 End play page 7 6 Inspection page 7 14 Installation...

Page 234: ...ion step 1 on page 7 20 Inspection step 1 on page 7 19 End play page 7 6 Small end measurement step 1 on page 7 19 Clearance page 7 9 Selection page 7 9 Inspection step 1 on page 7 23 Tightening step...

Page 235: ...a feeler gauge A between the connecting rod B and crankshaft C 4 If the connecting rod end play is out of tolerance install a new connecting rod and recheck If it is still out of tolerance replace th...

Page 236: ...jack under the counterweights and check only one bearing at a time 4 Reinstall the bearings and caps then torque the bolts see step 21 on page 7 25 Do not rotate the crankshaft 5 Remove the caps and...

Page 237: ...w Yellow Green Brown Green Brown Brown Green Yellow Green Pink Yellow Yellow Green Pink Yellow Pink Green Brown Brown Black Green Brown Red Pink Pink Pink Yellow Yellow Green Yellow Yellow Green Green...

Page 238: ...8 on page 7 25 Do not rotate the crankshaft 5 Remove the rod cap and bearing half and measure the widest part of the plastigage 6 If the plastigage measures too wide or too narrow remove the upper hal...

Page 239: ...Color code is on the edge of the bearing A or I B or II C or III D or IIII E or IIIII F or IIIIII 1 Inspect the connecting rod for cracks and heat damage 2 Each rod has a tolerance range from 0 to 0...

Page 240: ...l in the vehicle drain the engine oil see page 8 5 2 Remove the exhaust pipe A see step 32 on page 5 7 3 Remove the torque converter cover A and the two bolts B securing the transmission 4 Remove the...

Page 241: ...rankshaft position CKP sensor A from the oil pump then remove the timing belt drive pulley B 5 Remove the oil pan see page 7 11 6 Remove the engine block end cover 7 Remove the oil screen A baffle pla...

Page 242: ...g from the cap Keep all caps bearings in order 11 Remove the upper bearing halves from the connecting rods and set them aside with their respective caps 12 After removing a piston connecting rod assem...

Page 243: ...der block being careful not to damage the journals 17 Reinstall the main caps and bearings on the cylinder block in the proper order 1 Remove the crankshaft from the cylinder block see page 7 12 2 Cle...

Page 244: ...RT DIAMETER 6 Place the cylinder block on the surface plate 7 Clean and install the bearings on the No 1 and No 4 journal of the cylinder block 8 Lower the crankshaft into the block 9 Measure the runo...

Page 245: ...Warpage Standard New 0 07 mm 0 003 in max Service Limit 0 10 mm 0 004 in 7 16 Engine Block Block and Piston Inspection cont d Y X Precision Straight Edge 4 Measure wear and taper in directions X and Y...

Page 246: ...atch pattern NOTE Use only a rigid hone with 400 grit or finer stone such as Sunnen Ammco or equivalent Do not use stones that are worn or broken 3 When honing is complete thoroughly clean the cylinde...

Page 247: ...m in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores B NOTE Take care not to damage the ring grooves 3 Remove both snap rings A Start at the cutout in the pis...

Page 248: ...onnecting Rod Clearance Standard New 0 005 0 014 mm 0 0002 0 0006 in Service Limit 0 019 mm 0 0007 in 7 19 NOTE Inspect the piston piston pin and connecting rod when they are at room temperature 1 Mea...

Page 249: ...in snap ring A 2 Coat the piston pin bore in the piston the bore in the connecting rod and the piston pin with new engine oil 3 Heat the piston to about 158 F 70 C 4 Install the piston pin A Assemble...

Page 250: ...n grooves File down the blade if necessary Top ring and second ring grooves are 1 2 mm 0 05 in wide and the oil ring groove is 2 8 mm 0 11 in wide Do not use a wire brush to clean the ring grooves or...

Page 251: ...cond Ring Standard A 3 4 mm 0 13 in B 1 2 mm 0 05 in A B C C A Top Ring Standard A 3 1 mm 0 12 in B 1 2 mm 0 05 in OIL RING GAP About 90 SECOND RING GAP PISTON PIN OIL RING GAP About 45 TOP RING GAP a...

Page 252: ...rence in diameter between point A and point B 3 If the difference in diameter is out of tolerance replace the connecting rod bolt 4 Check the connecting rod bearing clearance with plastigage see page...

Page 253: ...nd check that the bearing is securely in place 14 Install the piston with the arrow A facing the timing belt side of the engine 15 Position the piston in the cylinder and tap it in using the wooden ha...

Page 254: ...od A and bolt head B as shown 20 Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod turn the bolt 90 21 Torque the bearing cap bolts A then torque the bearin...

Page 255: ...gasket P N 08718 0001 or 08718 0003 evenly to the block mating surface of the engine block end cover and to the inner threads of the bolt holes Install the dowel pins A new O ring B and the left side...

Page 256: ...grease to the lip of the oil seal and apply new engine oil to the new O ring B 4 Install the dowel pins C then align the inner rotor with the crankshaft and install the oil pump 5 Clean the excess gr...

Page 257: ...Tighten the two bolts A securing the transmission then install the torque converter cover B 7 Install the exhaust pipe A see step 19 on page 8 Apply liquid gasket along the broken line Remove any old...

Page 258: ...ms against the oil pump When the seal is in place clean any excess grease off the crankshaft and check that the oil seal lip is not distorted Driver 07749 0010000 Driver attachment 106 070AD RCA0200 1...

Page 259: ......

Page 260: ...t Location Index 8 3 Oil Pressure Switch Test 8 4 Oil Pressure Test 8 4 Engine Oil Replacement 8 5 Engine Oil Filter Replacement 8 5 Oil Filter Feed Pipe Replacement 8 7 Oil Pump Overhaul 8 8 Oil Pres...

Page 261: ...Ref No Tool Number Description Qty 8 2 Engine Lubrication Special Tools 070AD RCA0100 1 07912 6110001 Oil Filter Wrench 1 03 07 29 09 13 41 61S0X050_080_0002 Oil Seal Driver 64 mm...

Page 262: ...SOLENOID VALVE FILTER OIL PUMP DRAIN BOLT WASHER OIL PAN DOWEL PIN BAFFLE PLATE O RING DOWEL PIN O RING OIL SCREEN OIL FILTER FEED PIPE Circuit Diagram page 22 96 Switch test page 8 4 Oil pressure tes...

Page 263: ...3 If the switch fails to operate check the engine oil level If the engine oil level is OK check the engine oil pressure If the oil pressure warning light stays on with the engine running check the eng...

Page 264: ...her oil change Under severe conditions the oil filter should be replaced at each oil change 1 Warm up the engine 2 Remove the drain bolt A and drain the engine oil 3 Reinstall the drain bolt with a ne...

Page 265: ...the following procedure to tighten the filter Spin the filter on until its seal lightly seats against the block and note which number is at the bottom Tighten the filter by turning it clockwise seven...

Page 266: ...eed pipe 3 Install the two 20 x 1 5 mm nuts A onto the new oil filter feed pipe Hold the nut with a wrench then tighten the other nut 4 Tighten the oil filter feed pipe to the block to 49 N m 5 0 kgf...

Page 267: ...OTOR INNER ROTOR PUMP HOUSING 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf ft SEALING BOLT 39 N m 4 0 kgf m 29 lbf ft SPRING RELIEF VALVE 1 8 in BSPT British standard pipe taper 28 threads inch Use the proper...

Page 268: ...hain hoist to the engine hanger on the power steering P S pump bracket see step 48 on page 5 10 6 Remove the jack from under the oil pan 7 Remove the VTEC solenoid valve and oil filter assembly see pa...

Page 269: ...ice limit replace the oil pump assembly 5 Inspect both rotors and pump housing for scoring or other damage Replace parts if necessary 6 Apply liquid thread lock to the pump housing screws then install...

Page 270: ...istortion 6 Install the oil screen D 7 Clean and dry the oil pan mating surfaces 8 Apply liquid gasket part No 08718 0001 or 08718 0003 evenly to the oil pan mating surface of the block and to the inn...

Page 271: ...l Pressure Switch Replacement 18 N m 1 8 kgf m 13 lbf ft 1 Disconnect the oil pressure switch connector then remove the oil pressure switch 2 Apply liquid gasket to the oil pressure switch then instal...

Page 272: ...anical Intake Manifold and Exhaust System Intake Manifold Removal and Installation 9 2 Exhaust Manifold Removal and Installation 9 10 Exhaust Pipe and Muffler Replacement 9 11 03 07 29 09 14 13 61S0X0...

Page 273: ...ft O RING 12 x 1 5 mm 26 N m 2 7 kgf m 20 lbf ft 99 model 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft THROTTLE BODY DOWEL PIN SPACER INTAKE MANIFOLD INTAKE AIR TEMPERATURE IAT SENSOR 18 N m 1 8 kgf m 13 lb...

Page 274: ...13 lbf ft GASKET GASKET GASKET GASKET GASKET 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf ft REAR INTAKE MANIFOLD CHAMBER FRONT INTAKE MANIFOLD CHAMBER UPPER COVER INTAKE MANIFOLD FUNNEL INTAKE MANIFOLD FUNNE...

Page 275: ...Manifold Removal and Installation cont d B A B B A A C B D A C B D 1 Remove the intake manifold cover A and ignition coil cover s B 2 Remove the evaporative emission EVAP canister hose A 1999 2001 mo...

Page 276: ...h a new one 5 Remove the engine wire harness connectors and wire harness clamps from the intake manifold Intake air temperature IAT sensor connector Idle air control IAC valve connector Throttle posit...

Page 277: ...ation cont d B A B A B C A C B 8 Remove the breather hose A and water bypass hoses B then plug the water bypass hoses 9 Remove the EVAP canister hose C 2002 2004 models 10 Remove the intake manifold 1...

Page 278: ...ft 9 7 1 Put the gasket and spacer on the injector base 2002 2004 models 2 Install the intake manifold Tighten the bolts and new intake manifold gasket 3 Install the upper cover Tighten the bolts and...

Page 279: ...B A C A B 4 Install the breather hose A and water bypass hoses B 5 Install the EVAP canister hose C 2002 2004 models 6 Install the brake booster vacuum hose A and PCV hose B 7 Install the vacuum hoses...

Page 280: ...s B and breather pipe C 11 Install the EVAP canister hose D 1999 2001 models or vacuum hose D 2002 2004 models 12 Install the ignition coil cover s A and intake manifold cover B 13 Clean up any spille...

Page 281: ...m 3 2 kgf m 23 lbf ft GASKET COVER 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft REAR EXHAUST MANIFOLD COVER SELF LOCKING NUT 8 x 1 25 mm 31 N m 3 2 kgf m 23 lbf ft GASKET NOTE Use new gaskets and self locki...

Page 282: ...f m 28 lbf ft SELF LOCKING NUT 10 x 1 25 mm 33 N m 3 4 kgf m 25 lbf ft SELF LOCKING NUTS 10 x 1 25 mm 54 N m 5 5 kgf m 40 lbf ft GASKETS EXHAUST PIPE A PRIMARY HEATED OXYGEN SENSOR PRIMARY HO2S 44 N m...

Page 283: ......

Page 284: ...nt Replacement 10 13 Thermostat Replacement 10 15 Radiator and Fan Replacement 10 16 Component Location Index 10 19 Symptom Troubleshooting Index 10 20 Circuit Diagram 10 21 Radiator and Condenser Fan...

Page 285: ...ADIATOR CAP RADIATOR ATF COOLER HOSES FAN MOTOR RADIATOR FAN SHROUD RADIATOR FAN A C CONDENSER FAN ASSEMBLY DRAIN PLUG O RING RESERVOIR TANK Replacement page 10 16 Test page 10 11 Replacement page 10...

Page 286: ...ls 10 3 UPPER RADIATOR HOSE WATER BYPASS HOSES HEATER HOSES HEATER VALVE THERMOSTAT COVER WATER PASSAGE LOWER RADIATOR HOSE RADIATOR UPPER RADIATOR HOSE HEATER HOSES HEATER VALVE THERMOSTAT COVER LOWE...

Page 287: ...SWITCH B DOWEL PIN EXHAUST GAS RECIRCULATION EGR VALVE ENGINE COOLANT TEMPERATURE ECT SENSOR O RINGS GASKET COOLANT TEMPERATURE GAUGE SENDING UNIT 1999 2000 models GASKETS RADIATOR FAN SWITCH A O RING...

Page 288: ...re to do so may damage the gauge If the pointer of the gauge does not move at all check for an open in the YEL GRN wire If the wires are OK replace the coolant temperature gauge If the coolant tempera...

Page 289: ...ssembly connector terminal C2 Replace the fuel and temperature gauge assembly Repair an open in the wire between PCM connector terminal E14 and gauge connector terminal C2 1 Turn the ignition switch O...

Page 290: ...disconnect the negative cable from the battery Then disconnect PCM connector E 31P 2 Connect the negative cable to the battery Turn the ignition switch ON II and watch the coolant temperature gauge Go...

Page 291: ...Connect the negative cable to the battery Turn the ignition switch ON II and watch the coolant temperature gauge Go to step 3 Substitute a known good PCM and recheck see page 11 5 If the symptom indi...

Page 292: ...e the fuel and temperature gauge assembly 1 Disconnect the YEL GRN wire A from the coolant temperature gauge sending unit B 2 Using an ohmmeter measure the change in resistance between the positive te...

Page 293: ...eck for a drop in pressure 4 If the pressure drops replace the cap 1 Wait until the engine is cool then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the fi...

Page 294: ...nal and the ground to the A terminal 3 If the motor fails to run or does not run smoothly replace it Replace the thermostat if it is open at room temperature To test a closed thermostat 1 Suspend the...

Page 295: ...bleed holes A is normal 1 Drain the engine coolant see page 10 13 2 Remove the timing belt see page 6 20 3 Remove the timing belt tensioner 4 Remove the water pump A by removing five bolts 5 Inspect...

Page 296: ...the drain bolt B located at the rear of the cylinder block then loosen the drain bolt 5 When the coolant stops draining tighten the drain bolt 6 Tighten the radiator drain plug securely 7 Remove drain...

Page 297: ...2 if needed 17 Set the temperature control dial to maximum Start the engine Hold the engine speed at 1 500 rpm for 3 minutes then turn off the engine 18 Check the level in the radiator and add Honda A...

Page 298: ...thermostat cover then remove the thermostat 6 Install the thermostat with new rubber seal 7 Install the battery Clean the battery posts and cable terminals with sandpaper then assemble them and apply...

Page 299: ...igation system then write down the frequencies for the radio s preset buttons 2 Disconnect the negative cable from the battery first then disconnect the positive cable 3 Drain the engine coolant see p...

Page 300: ...ve the three mounting bolts A and loosen mounting bolt B then remove the battery base C 10 Remove the harness clamps A then remove the fan motor connectors B and A C compressor clutch connector C 11 R...

Page 301: ...ng bolts D securing the condenser fan shroud then remove the condenser fan shroud assembly E from the battery side 16 Pull up the radiator A then remove the lower cushions B ATF cooler line C radiator...

Page 302: ...AN RELAY A C CONDENSER FAN ASSEMBLY RADIATOR FAN ASSEMBLY CONDENSER FAN RELAY RADIATOR FAN SWITCH A RADIATOR FAN SWITCH B RELAY BOX RADIATOR FAN MAIN RELAY Test page 22 88 Motor Test page 10 11 Motor...

Page 303: ...A C ON and when the engine coolant temperature is above 210 F 99 C Radiator and condenser fan circuit troubleshooting B see page 10 23 Both radiator and condenser fans do not run when the engine cool...

Page 304: ...TOR G101 Closed Above 210 F 99 C BLU RED BLU RED GRN BLU RED GRN 1 2 BLU RED BLK YEL BLK YEL FAN MOTOR CONDENSER BLU RED SYSTEM AIR CONDITIONING DRIVER S GRN BLU YEL RELAY FAN CONDENSER UNDER HOOD FUS...

Page 305: ...22 88 Go to step 3 Replace radiator fan relay 3 Measure the voltage between radiator fan relay 4P socket terminal No 1 and body ground Go to step 4 Replace the under hood fuse relay box 4 Connect a ju...

Page 306: ...diator fan motor NOTE Refer to the symptom troubleshooting index before troubleshooting 1 Disconnect the radiator fan switch A 2P connector 2 Turn the ignition switch ON II 3 Measure the voltage betwe...

Page 307: ...adiator fan switch B 2P connector terminal No 1 and A C pressure switch Go to step 6 6 Disconnect the radiator fan switch A 2P connector and turn the ignition switch ON II Replace radiator fan switch...

Page 308: ...e radiator fan switch B Repair an open in the wire between radiator fan switch B 2P connector terminal No 2 and ground G101 1 Remove radiator fan switch A from the water passage and radiator fan switc...

Page 309: ......

Page 310: ...ieving 11 215 Fuel Pressure Test 11 216 Fuel Pump Test 11 218 Fuel Line Inspection 11 219 Fuel Tube Quick Connect Fitting Precaution 11 223 Fuel Tube Quick Connect Fitting Removal 11 224 Fuel Tube Qui...

Page 311: ...s A973X 041 XXXXX Vacuum Pump Gauge 0 30 in Hg 1 07JAZ 001000B Vacuum Pressure Gauge 0 4 in Hg 1 07SAZ 001000A Backprobe Set 2 07VAJ 0040100 Fuel Pressure Gauge Attachment 1 07XAA 001010A Fuel Sender...

Page 312: ...switch is turned ON II and the engine is not started the MIL will stay on for 15 20 seconds see page 11 89 2 If the MIL stays on connect the HDS or an OBD II scan tool to the Data Link Connector DLC A...

Page 313: ...1 Reset the PCM as described above 2 Turn the ignition switch OFF 3 Disconnect the OBD II scan tool or HDS from the DLC 4 Do the idle learn procedure see page 11 202 NOTE The PCM is part of the immob...

Page 314: ...ows you to swap a PCM from a donor vehicle without having to program it to the test vehicle s ignition key 1 Cut a temporary ignition key for the test vehicle with a non immobilizer key blank 2 Remove...

Page 315: ...h Voltage ON see page 11 120 P0133 61 P0133 Primary Heated Oxygen Sensor Primary HO2S ON see page 11 122 P0135 41 Primary Heated Oxygen Sensor Primary HO2S Sensor 1 Heater Circuit Malfunction ON see p...

Page 316: ...0450 ON see page 11 266 P0461 121 Fuel Level Sensor Fuel Gauge Sending Unit Range Performance Problem OFF see page 11 205 P0462 121 Fuel Level Sensor Fuel Gauge Sending Unit Circuit Low Voltage OFF se...

Page 317: ...n ON see page 11 184 P1607 Powertrain Control Module PCM Internal Circuit Malfunction ON see page 11 165 P1676 35 FPTDR Signal Line Failure ON see page 11 161 P1678 35 FPTDR Signal Line Failure ON see...

Page 318: ...able see page 11 242 Inspect and test the throttle body see page 11 237 Idle speed fluctuates MIL works OK no DTCs set 1 2 3 4 Do the idle learn procedure see page 11 202 Check the idle speed see page...

Page 319: ...e memory When the ignition is first turned on the PCM supplies ground to the MIL for 2 seconds 99 01 models or for 15 to 20 seconds 02 04 models to check the MIL bulb condition To prevent false indica...

Page 320: ...30 50 rpm YES Vehicle Speed The PCM converts pulse signals from the output shaft countershaft speed sensor into speed data Nearly the same as speedometer indication YES Manifold Absolute Pressure MAP...

Page 321: ...unt of injected fuel This cycle keeps the air fuel ratio close to the stoichiometric ratio when in closed loop status 0 6 1 5 YES Long Term Fuel Trim Long term fuel trim is computed from short term fu...

Page 322: ...R A15 INJ1 B11 INJ2 B5 INJ3 B15 INJ4 B4 INJ5 B3 INJ6 B6 IACV B23 C20 TDC1 C8 CKP C9 CKP A30 ELD A9 VSSOUT MIL A18 INJECTORS A10 SCS ALTC C2 ALTF C5 A21 K LINE ACC A17 FANC A20 ACS A27 TDC SENSOR 2 CKP...

Page 323: ...S SOLENOID VALVE EVAP CONTROL CANISTER VENT SHUT VALVE To IMMOBILIZER UNIT To IMMOBILIZER UNIT To GAUGE ASSEMBLY To CRUISE CONTROL UNIT TEST TACHOMETER CONNECTOR E EVAP PURGE CONTROL SOLENOID VALVE IC...

Page 324: ...VE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B NC D10 NMSG D12 NM D11 LSB B18 LSB B25 LSA B8 LSA B17 SHC D3 SHB D2 NCSG D16 ABS TCS CONTROL UNIT 2ND CLUTCH PRESSURE SWITCH 3RD CLUTCH PRESSURE SWITC...

Page 325: ...LG2 PG1 A5 PG2 A4 IMOFPR E1 INJ1 B14 INJ2 B13 INJ3 B12 INJ4 B22 INJ5 B21 INJ6 B20 IACV B23 A11 TDC1 A12 CKP A24 CKP E19 ELD E26 VSSOUT MIL E4 INJECTORS E16 SCS ALTC B6 ALTF A19 E27 K LINE ACC E12 FAN...

Page 326: ...IMMOBILIZER UNIT To MULTIPLEX CONTROL UNIT DRIVERS To GAUGE ASSEMBLY To CRUISE CONTROL UNIT TEST TACHOMETER CONNECTOR E EVAP CANISTER PURGE VALVE ICM No 2 IGNITION COIL To SPARK PLUG ICM No 3 IGNITION...

Page 327: ...VE A SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B NC C15 NMSG C5 NM C7 LSB C8 LSB B16 LSA C1 LSA B7 SHC C17 SHB C9 NCSG C14 ABS TCS CONTROL UNIT 2ND CLUTC...

Page 328: ...FPR A15 INJ1 B11 INJ2 B5 INJ3 B15 INJ4 B4 INJ5 B3 INJ6 B6 IACV B23 C20 C21 C29 C30 C8 CKP C9 CKP A30 ELD A9 VSSOUT MIL A18 INJECTORS A10 SCS ALTC C2 ALTF C5 A21 K LINE ACC A17 FANC A20 ACS A27 CMP SEN...

Page 329: ...VALVE EVAP CANISTER VENT SHUT VALVE To IMMOBILIZER CONTROL UNIT RECEIVER To GAUGE ASSEMBLY To CRUISE CONTROL UNIT TEST TACHOMETER CONNECTOR E EVAP CANISTER PURGE VALVE ICM No 2 IGNITION COIL To SPARK...

Page 330: ...SSURE CONTROL SOLENOID VALVE C NC D10 NMSG D12 NM D11 LSC B24 LSC B13 LSB B18 LSB B25 LSA B8 LSA B17 SHC D3 SHB D2 NCSG D16 ABS TCS CONTROL UNIT 4TH CLUTCH PRESSURE SWITCH 3RD CLUTCH PRESSURE SWITCH G...

Page 331: ...ARY HEATED OXYGEN SENSOR HEATER CONTROL Drives secondary HO2S heater With ignition switch ON II battery voltage With fully warmed up engine running duty controlled 9 BLU WHT VSSOUT VEHICLE SPEED SENSO...

Page 332: ...ltage With starter switch OFF 0 V 25 RED IMOCD IMMOBILIZER CODE Detects immobilizer signal 26 GRN PSPSW P S PRESSURE SWITCH SIGNAL Detects PSP switch signal At idle with steering wheel in straight ahe...

Page 333: ...le duty controlled 12 GRN YEL VTSOL VTEC SOLENOID VALVE Drives VTEC solenoid valve With engine at low rpm 0 V With engine at high rpm battery voltage 14 BLU WHT ATPNP AT GEAR POSITION SWITCH Detects A...

Page 334: ...COIL PULSE Drives No 2 ignition coil 16 WHT PHO2S PRIMARY HEATED OXYGEN SENSOR SENSOR 1 Detects primary heated oxygen sensor sensor 1 signal With throttle fully opened from idle with fully warmed up...

Page 335: ...l solenoid valve A With engine running in 2nd 3rd gears battery voltage With engine running in 1st 4th gears about 0 V 8 PNK ATPD3 AT GEAR POSITION SWITCH Detects A T gear position switch signal In D3...

Page 336: ...OWERTRAIN TORQUE DOWN REQUEST Detects engine retard request signal With TCS operating about 5 V With TCS not operating about 2 5 V 3 LT GRN RED PFINH POWERTRAIN TO FRAME INHIBITION Sends TCS operation...

Page 337: ...temperature 14 RED YEL IAT INTAKE AIR TEMPERATURE IAT SENSOR Detects IAT sensor signal With ignition switch ON II about 0 1 4 8 V depending on intake air temperature 15 RED BLK TPS THROTTLE POSITION T...

Page 338: ...N COIL PULSE Drives No 2 ignition coil 10 YEL GRN IGPLS1 No 1 IGNITION COIL PULSE Drives No 1 ignition coil 12 BLU INJ3 No 3 INJECTOR Drives No 3 injector With ignition switch ON II battery voltage At...

Page 339: ...ck up OFF about 0 V 11 BLU BLK OP2SW 2ND OIL PRESSURE SWITCH Detects 2nd oil pressure switch With the ignition switch ON II battery voltage 12 BLU ATP2 TRANSMISSION RANGE 2 POSITION SWITCH Detects tra...

Page 340: ...sion normal about 2 5 V Inhibition engine coolant temperature below 32 F 0 C about 5 V Failure TCS and or PCM is failure 0 V 9 WHT RED VREF REFERENCE VOLTAGE Provides reference voltage to ABS TCS cont...

Page 341: ...h signal With starter switch OFF about 0 V 9 WHT BLK BKSW BRAKE PEDAL POSITION SWITCH Detects brake pedal position switch signal With brake pedal released about 0 V 11 RED YEL PCS EVAPORATIVE EMISSION...

Page 342: ...RATIVE EMISSION EVAP CANISTER VENT SHUT VALVE Drives EVAP canister vent shut valve With ignition switch ON II battery voltage 23 BLU 2WBS EVAPORATIVE EMISSION EVAP BYPASS SOLENOID VALVE Drives EVAP by...

Page 343: ...signal With ignition switch ON II pulses 6 RED YEL PCS EVAP CANISTER PURGE VALVE Drives EVAP canister purge valve With engine running engine coolant below 147 F 64 C battery voltage With engine runnin...

Page 344: ...SIGNAL Detects PSP switch signal At idle with steering wheel in straight ahead position 0 V At idle with steering wheel at full lock battery voltage 27 BLU RED ACS A C SWITCH SIGNAL Detects A C switc...

Page 345: ...CLUTCH PRESSURE CONTROL SOLENOID VALVE C SIDE Drives A T clutch pressure control solenoid valve C With the ignition switch ON II duty controlled 14 BLU WHT ATPNP TRANSMISSION RANGE SWITCH N P POSITIO...

Page 346: ...eated oxygen sensor sensor 1 signal With throttle fully opened from idle with fully warmed up engine above 0 6 V With throttle quickly closed below 0 4 V 17 GRN RED MAP MANIFOLD ABSOLUTE PRESSURE SENS...

Page 347: ...5th gears battery voltage With engine running in 3rd and 4th gears about 0 V 8 RED ATPD3 TRANSMISSION RANGE SWITCH D3 Detects transmission range switch D3 signal In D3 position 0 V In any other posit...

Page 348: ...ON II about 5 V With ignition switch OFF 0 V 7 LT GRN RED PFINH POWERTRAIN TO FRAME INHIBITION Sends TCS operation permission signal Permission normal about 2 5 V Inhibition engine coolant temperatur...

Page 349: ...d MANIFOLD ABSOLUTE PRESSURE MAP SENSOR To ENGINE MOUNT CONTROL SOLENOID VALVE To EVAPORATIVE EMISSION EVAP CONTROL CANISTER EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE FUEL PRESSURE REGULATOR FRO...

Page 350: ...ABSOLUTE PRESSURE MAP SENSOR To ENGINE MOUNT CONTROL SOLENOID VALVE To EVAPORATIVE EMISSION EVAP CONTROL CANISTER EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE FUEL PRESSURE REGULATOR FRONT OF VEHICL...

Page 351: ...SENSOR PRIMARY HO2S SENSOR 1 SECONDARY HEATED OXYGEN SENSOR SECONDARY HO2S SENSOR 2 INJECTOR FUEL PULSATION DAMPER RESONATOR KNOCK SENSOR KS AIR TEMPERATURE CONTROL VALVE AIR VALVE EXHAUST GAS RECIRC...

Page 352: ...ISTER FILTER EVAPORATIVE EMISSION EVAP CANISTER THREE WAY CATALYTIC CONVERTER POSITIVE CRANKCASE VENTILATION PCV VALVE FUEL TANK EVAPORATIVE EMISSION EVAP VALVE FUEL TANK VAPOR CONTROL VALVE FUEL TANK...

Page 353: ...NISTER VENT SHUT VALVE EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE EVAPORATIVE EMISSION EVAP CONTROL CANISTER FILTER EVAPORATIVE EMISSION EVAP CANISTER THREE WAY CATALYTIC CONVERTER POSITIVE CRANKC...

Page 354: ...The BARO sensor is inside the PCM It converts atmospheric pressure into a voltage signal that modifies the basic duration of the fuel injection discharge The CMP TDC A B sensor input is used by the PC...

Page 355: ...N II but do not start the engine The MIL will come on for 15 20 seconds If it then goes off the readiness codes are set to complete If it blinks several times the readiness codes are not set to comple...

Page 356: ...CM sets a DTC The secondary HO2S detects the oxygen content in the exhaust gas downstream of the three way catalytic converter TWC and sends signals to the PCM which varies the duration of fuel inject...

Page 357: ...the PGM FI main relay which feeds current to the fuel pump for 2 seconds to pressurize the fuel system With the engine running the PCM grounds the PGM FI main relay and feeds current to the fuel pump...

Page 358: ...jectors The throttle body is a single barrel side draft type The lower portion of the throttle valve is heated by engine coolant from the cylinder head The idle adjusting screw which increases decreas...

Page 359: ...r from the fuel tank until it can be purged into the engine and burned When the engine coolant temperature is below 147 F 64 C the PCM turns off the EVAP canister purge valve which cuts vacuum to the...

Page 360: ...L THERMAL VALVE ENGINE COOLANT BLK The idle speed of the engine is controlled by the idle air control IAC valve After the engine starts the IAC valve opens for a certain amount of time The amount of a...

Page 361: ...es of nitrogen NOx emissions by recirculating exhaust gas through the EGR valve and the intake manifold into the combustion chambers The PCM memory includes the ideal EGR valve lift for varying operat...

Page 362: ...controls minimize the amount of fuel vapor escaping to the atmosphere Vapor from the fuel tank is temporarily stored in the EVAP control canister until it can be purged from the canister into the engi...

Page 363: ...SENSORS LT GRN WHT PCM The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere Vapor from the fuel tank is temporarily stored in the EVAP control canister until it can be purged...

Page 364: ...UT VALVE from No 6 ECU PCM CRUISE CONTROL 15A in the driver s under dash fuse relay box FUEL TANK VAPOR RECIRCULATION TUBE FUEL FILL CAP FUEL TANK VAPOR RECIRCULATION VALVE FUEL TANK EVAP BYPASS SOLEN...

Page 365: ...YEL BLU VCC1 BLK GRN BLK WHT BLK MAP SG1 ECT IAT VCC2 TPS EGRP EGR SG2 JUNCTION CONNECTOR D YEL BLU GRN BLK GRN BLK GRN BLK YEL RED RED GRN GRN WHT RED WHT RED YEL RED BLK WHT BLK YEL BLU GRN BLK RED...

Page 366: ...RN YEL BLK YEL BLK YEL BRN BLK BRN BLK GRN BLK BLK YEL JUNCTION CONNECTOR D C101 PRIMARY HO2S SENSOR 1 VTEC SOLENOID VALVE VTEC OIL PRESSURE SWITCH JUNCTION CONNECTOR B JUNCTION CONNECTOR C G101 B2 VT...

Page 367: ...B8 LSB LSB YEL BLU YEL GRN WHT GRN RED WHT BLU GRN RED WHT ORN GRN G E BLK BLK LOCK UP CONTROL SOLENOID VALVE SHIFT CONTROL SOLENOID VALVE B SHIFT CONTROL SOLENOID VALVE C INPUT SAHFT MAINSHAFT SPEED...

Page 368: ...RED INJ6 WHT BLU IACV BLK BLU IGP1 YEL BLK I YEL BLK YEL BLK YEL BLK YEL BLK YEL BLK YEL BLK YEL BLK BLK No 1 INJECTOR No 2 INJECTOR No 3 INJECTOR No 4 INJECTOR No 5 INJECTOR No 6 INJECTOR IAC VALVE J...

Page 369: ...OR To TACHOMETER GAUGE ASSEMBLY CRUISE CONTROL UNIT SECONDARY HO2S SENSOR 2 ENGINE MOUNT CONTROL SOLENOID VALVE PURGE VALVE G201 C203 C303 C203 WHT RED PNK SHO2S GRN BLK BLK YEL BLK WHT BLK YEL GRN WH...

Page 370: ...To IMMOBILIZER UNIT J K MIL P R N D D 2 1 P R N D D 2 1 DRIVER S UNDER DASH FUSE RELAY BOX GAUGE ASSEMBLY A T GEAR POSITION SWITCH JUNCTION CONNECTOR D RED BLK PNK BLU BRN BLU BLK WHT WHT BLU WHT RED...

Page 371: ...BOX IGNITION SWITCH IG1 ST B Z BLK YEL EVAP CANISTER VENT SHUT VALVE EVAP BYPASS SOLENOID VALVE LT GRN WHT YEL BLU LT GRN GRN BLK BLU BLK YEL YEL BLU GRN BLK BLK YEL GRN BLK BLK YEL YEL BLU BLK YEL B...

Page 372: ...552 U Q F W I T S GRN YEL BLU ORN RED WHT BLK YEL BLK WHT YEL WHT WHT BLK LT BLU BLK YEL BLK YEL RED WHT WHT YEL WHT BLK BLK YEL BLK BRN BLK YEL BLK WHT GRN BLK WHT GRY BRN BLU ORN C203 CONNECTOR Q CO...

Page 373: ...D ACC N BLK YEL YEL To A C PRESSURE SWITCH O P L U R V S Q T C203 CONNECTOR C CONNECTOR B CONNECTOR D CONNECTOR C CONNECTOR A BRN BLK BLU RED WHT YEL WHT BLK RED BLK YEL BRN BLK BLK YEL BLU RED WHT YE...

Page 374: ...PLUG No 5 IGNITION COIL ICM To SPARK PLUG No 6 IGNITION COIL JUNCTION CONNECTOR B JUNCTION CONNECTOR B BLK YEL BLK C4 IGPLS1 IGPLS2 IGPLS4 IGPLS5 IGPLS6 C3 IGPLS3 RED YEL GRN BLU YEL BLK YEL BLK BLK...

Page 375: ...nd Emissions Systems System Descriptions cont d A11 A31 ATSFTP LT GRN A7 VREF WHT RED TPSOUT RED BLK E3 PFINH LT GRN RED E1 FPTDR PNK BLK AA C504 LT GRN RED PNK BLK C302 LT GRN ORN WHT RED BLU BLU PNK...

Page 376: ...ECTOR D YEL BLU VCC1 BLK GRN BLK WHT BLK MAP SG1 ECT IAT VCC2 TPS EGRP EGR SG2 JUNCTION CONNECTOR D YEL BLU GRN BLK GRN BLK GRN BLK YEL RED RED GRN GRN WHT RED WHT RED YEL RED BLK WHT BLK YEL BLU GRN...

Page 377: ...D YEL BLU WHT H B F G E A BLK BLU BLK BLK WHT WHT BLK YEL GRN YEL BLK YEL BLK YEL BRN BLK BRN BLK GRN BLK BLK YEL JUNCTION CONNECTOR B C101 PRIMARY HO2S SENSOR 1 VTEC SOLENOID VALVE VTEC OIL PRESSURE...

Page 378: ...ED WHT ORN GRN G E BLK BLK TORQUE CONVERTER CLUTCH SOLENOID VALVE SHIFT CONTROL SOLENOID VALVE B SHIFT CONTROL SOLENOID VALVE C INPUT SAHFT MAINSHAFT SPEED SENSOR OUTPUT SAHFT COUNTERSHAFT SPEED SENSO...

Page 379: ...LK H JUNCTION CONNECTOR A INJ2 RED INJ3 BLU INJ4 YEL INJ5 BLK RED INJ6 WHT BLU IACV BLK BLU IGP1 YEL BLK I YEL BLK YEL BLK YEL BLK YEL BLK YEL BLK YEL BLK YEL BLK BLK No 1 INJECTOR No 2 INJECTOR No 3...

Page 380: ...ONTROL UNIT SECONDARY HO2S SENSOR 2 ENGINE MOUNT CONTROL SOLENOID VALVE PURGE VALVE G201 C203 C203 C203 WHT RED PNK SHO2S GRN BLK BLK YEL BLK WHT BLK YEL GRN WHT RED YEL BLK YEL WHT YEL BLU BLU GRN BL...

Page 381: ...3RD CLUTCH PRESSURE SWITCH To IMMOBILIZER CONTROL UNIT RECEIVER J K MIL P R N D D 2 1 P R N D D 2 1 DRIVER S UNDER DASH FUSE RELAY BOX GAUGE ASSEMBLY TRANSMISSION RANGE SWITCH JUNCTION CONNECTOR B RE...

Page 382: ...YEL EVAP CANISTER VENT SHUT VALVE EVAP BYPASS SOLENOID VALVE LT GRN WHT YEL BLU LT GRN GRN BLK BLU BLK YEL YEL BLU GRN BLK BLK YEL BLK YEL BLK YEL YEL BLU YEL GRN BLK BLU WHT WHT YEL CONNECTOR B CONNE...

Page 383: ...A LINK CONNECTOR BRAKE PEDAL POSITION SWITCH FUEL PUMP PGM FI MAIN RELAY G552 U Q F W I T S GRN YEL BLU ORN RED WHT BRN BLK YEL BLK BLK YEL BLK WHT YEL WHT WHT BLK LT BLU BLK YEL BLK YEL RED WHT WHT Y...

Page 384: ...R V S Q T C203 CONNECTOR C CONNECTOR B CONNECTOR D CONNECTOR C CONNECTOR A BRN BLK BLU RED WHT YEL WHT BLK RED BLK YEL BRN BLK BLK YEL BLU RED WHT YEL BRN BLK WHT GRN WHT YEL WHT YEL YEL BLK YEL GRN R...

Page 385: ...OIL ICM To SPARK PLUG No 4 IGNITION COIL ICM To SPARK PLUG No 5 IGNITION COIL ICM To SPARK PLUG No 6 IGNITION COIL JUNCTION CONNECTOR B JUNCTION CONNECTOR B BLK YEL BLK IGPLS1 IGPLS2 IGPLS4 IGPLS5 IGP...

Page 386: ...ATSFTP LT GRN D9 VREF WHT RED TPSOUT RED BLK D5 PFINH LT GRN RED FPTDR PNK BLK AA C302 LT GRN ORN WHT RED BLU BLU PNK ECTOUT YEL GRN BLU ABS TCS CONTROL UNIT To COOLANT TEMPERATURE GAUGE ASSEMBLY D3 w...

Page 387: ...JUNCTION CONNECTOR A JUNCTION CONNECTOR B G YEL BLU VCC1 BLK GRN YEL WHT BLK MAP SG1 ECT IAT VCC2 TPS EGRP EGR SG2 JUNCTION CONNECTOR B YEL BLU GRN YEL GRN YEL GRN YEL YEL RED GRN RED GRN WHT RED WHT...

Page 388: ...GRN YEL BLK YEL BLK YEL BRN YEL BRN YEL GRN YEL BLK YEL JUNCTION CONNECTOR B C101 PRIMARY HO2S SENSOR 1 VTEC SOLENOID VALVE VTEC PRESSURE SWITCH JUNCTION CONNECTOR C JUNCTION CONNECTOR B G101 B2 VTPS...

Page 389: ...TROL SOLENOID VALVE A LSA LSA RED WHT B17 B8 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B LSB LSB BRN WHT GRN A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C LSC LSC TORQUE CONVERTER CLUTCH SOLENOID VALV...

Page 390: ...SHAFT MAINSHAFT SPEED SENSOR OUTPUT SHAFT COUNTERSHAFT SPEED SENSOR No 2 INJECTOR INJ2 RED YEL BLK No 3 INJECTOR INJ3 BLU YEL BLK No 4 INJECTOR YEL INJ4 YEL BLK No 5 INJECTOR INJ5 BLK RED YEL BLK IAC...

Page 391: ...ICATOR To TACHOMETER GAUGE ASSEMBLY CRUISE CONTROL UNIT SECONDARY HO2S SENSOR 2 ENGINE MOUNT CONTROL SOLENOID VALVE EVAP CANISTER PURGE VALVE G201 C203 C203 C302 C203 WHT RED PNK SHO2S GRN BLK BLK YEL...

Page 392: ...PRESSURE SWITCH To IMMOBILIZER UNIT J K MIL P R N D D 2 1 P R N D D 2 1 DRIVER S UNDER DASH FUSE RELAY BOX GAUGE ASSEMBLY TRANSMISSION RANGE SWITCH JUNCTION CONNECTOR B RED BLK RED BLU BRN BLU BLK WH...

Page 393: ...S UNDER DASH FUSE RELAY BOX IGNITION SWITCH IG1 ST B Z BLK YEL EVAP CANISTER VENT SHUT VALVE EVAP BYPASS SOLENOID VALVE LT GRN WHT YEL BLU LT GRN GRN BLK BLU BLK YEL YEL BLU GRN BLK BLK YEL GRN BLK B...

Page 394: ...PGM FI MAIN RELAY G552 U Q F W I T S GRN YEL BLU ORN RED WHT BRN YEL YEL BLK BLK YEL BLK WHT YEL WHT WHT BLK LT BLU BLK YEL BLK YEL RED WHT WHT YEL WHT BLK BLK YEL BLK BLK BRN YEL YEL BLK WHT GRN BLK...

Page 395: ...BOX ELD ACC N BLK YEL YEL To A C PRESSURE SWITCH O P L U R V S Q T C203 CONNECTOR C CONNECTOR B CONNECTOR D CONNECTOR C CONNECTOR A BRN YEL BLU RED WHT YEL WHT BLK RED BLK YEL BRN BLK BLK YEL BLU RED...

Page 396: ...PLUG No 5 IGNITION COIL ICM To SPARK PLUG No 6 IGNITION COIL JUNCTION CONNECTOR B JUNCTION CONNECTOR A BLK YEL BLK C4 IGPLS1 C14 IGPLS2 C13 IGPLS4 C12 IGPLS5 C23 IGPLS6 C3 IGPLS3 BLU RED YEL GRN WHT...

Page 397: ...504 LT GRN WHT RED RED BLK LT GRN RED PNK BLK C302 ATF TEMPERATURE SENSOR BLU YEL GRN YEL BLU YEL GRN YEL ATFT AC LT GRN WHT RED RED BLK LT GRN RED PNK BLK ECTOUT YEL GRN FLS05 YEL BLU To FUEL GAUGE G...

Page 398: ...mplete To set readiness codes from incomplete to complete do the procedure for the appropriate code NOTE Do not turn the ignition switch OFF during the procedure All readiness codes are cleared when t...

Page 399: ...le s data link connector DLC and bring up the tool s generic OBD II mode 2 Start the engine 3 Test drive the vehicle under stop and go conditions with short periods of steady cruise During the drive d...

Page 400: ...ing met Monitoring resumes when the enable criteria is again being met This readiness code is always set to available because the comprehensive component monitor is continuously running whenever the e...

Page 401: ...POSITION CMP SENSOR A B PRIMARY HEATED OXYGEN SENSOR PRIMARY HO2S SENSOR 1 SECONDARY HEATED OXYGEN SENSOR SECONDARY HO2S SENSOR 2 Troubleshooting page 11 102 Troubleshooting page 11 158 Troubleshootin...

Page 402: ...99 00 models 01 model 11 93 INJECTORS INJECTORS cont d Replacement page 11 177 Replacement page 11 177...

Page 403: ...mponent Location Index cont d INJECTORS DATA LINK CONNECTOR DLC POWERTRAIN CONTROL MODULE PCM General Troubleshooting Information page 11 3 General Troubleshooting Information page 11 3 Replacement pa...

Page 404: ...ween PCM connector terminals C19 and C7 Repair open in the wire between the PCM C19 and the MAP sensor Substitute a known good PCM and recheck see page 11 5 If normal MAP readings are indicated replac...

Page 405: ...tage between PCM connector terminals A29 and A31 Repair open in the wire between the PCM A31 and the MAP sensor Substitute a known good PCM and recheck see page 11 5 If normal MAP readings are indicat...

Page 406: ...onnector terminals C19 and C7 Repair open in the wire between the PCM C19 and the MAP sensor Substitute a known good PCM and recheck see page 11 5 If normal MAP readings are indicated replace the orig...

Page 407: ...6 Turn the ignition switch ON II 7 Check the MAP with the scan tool or the HDS Go to step 8 Replace the MAP sensor 8 Remove the jumper wire 9 Measure voltage between MAP sensor 3P connector terminals...

Page 408: ...ch ON II 7 Check the MAP with the scan tool or the HDS Go to step 8 Replace the MAP sensor 8 Remove the jumper wire 9 Measure voltage between MAP sensor 3P connector terminals No 1 and No 3 Go to step...

Page 409: ...6 Turn the ignition switch ON II 7 Check the MAP with the scan tool or the HDS Go to step 8 Replace the MAP sensor 8 Remove the jumper wire 9 Measure voltage between MAP sensor 3P connector terminals...

Page 410: ...failure system is OK at this time Replace the MAP sensor 1 Start the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on then let it idle 2 Check the M...

Page 411: ...ground Repair short in the wire between the PCM C25 and the IAT sensor Substitute a known good PCM and recheck see page 11 5 If normal IAT readings are indicated replace the original PCM 8 Check the...

Page 412: ...e wire between the PCM A14 and the IAT sensor Substitute a known good PCM and recheck see page 11 5 If normal IAT readings are indicated replace the original PCM 8 Check the temperature reading on the...

Page 413: ...tor 5 Connect IAT sensor 2P connector terminals No 1 and No 2 with a jumper wire 6 Turn the ignition switch ON II 7 Check the IAT with the scan tool or the HDS Go to step 8 Replace the IAT sensor 8 Tu...

Page 414: ...umper wire 6 Turn the ignition switch ON II 7 Check the IAT with the scan tool or the HDS Go to step 8 Replace the IAT sensor 8 Turn the ignition switch OFF 9 Remove the jumper wire 10 Connect PCM con...

Page 415: ...cooling system Intermittent failure system is OK at this time 1 Turn the ignition switch ON II 2 Check the ECT with the scan tool or the HDS Go to step 3 Intermittent failure system is OK at this tim...

Page 416: ...he ECT with the scan tool or the HDS Go to step 5 Replace the ECT sensor 5 Turn the ignition switch OFF 6 Disconnect PCM connector A 31P 7 Check the continuity between ECT sensor 2P connector terminal...

Page 417: ...tor 5 Connect ECT sensor 2P connector terminals No 1 and No 2 with a jumper wire 6 Turn the ignition switch ON II 7 Check the ECT with the scan tool or the HDS Go to step 8 Replace the ECT sensor 8 Tu...

Page 418: ...umper wire 6 Turn the ignition switch ON II 7 Check the ECT with the scan tool or the HDS Go to step 8 Replace the ECT sensor 8 Turn the ignition switch OFF 9 Remove the jumper wire 10 Connect PCM con...

Page 419: ...he PCM Go to step 4 4 Turn the ignition switch OFF 5 Disconnect the TP sensor 3P connector 6 Turn the ignition switch ON II 7 Measure voltage between TP sensor 3P connector terminals No 1 and No 3 Go...

Page 420: ...eck for continuity between TP sensor 3P connector terminal No 2 and body ground Substitute a known good PCM and recheck see page 11 5 If the prescribed voltage is now available replace the original PC...

Page 421: ...OFF 5 Disconnect the TP sensor 3P connector 6 Turn the ignition switch ON II 7 Measure voltage between TP sensor 3P connector terminals No 1 and No 3 Go to step 8 Go to step 15 8 Turn the ignition sw...

Page 422: ...r continuity between TP sensor 3P connector terminal No 2 and body ground Substitute a known good PCM and recheck see page 11 5 If the prescribed voltage is now available replace the original PCM Repa...

Page 423: ...ime Check for poor connections or loose terminals at the TP sensor and the PCM Go to step 4 4 Turn the ignition switch OFF 5 Disconnect the TP sensor 3P connector 6 Turn the ignition switch ON II 7 At...

Page 424: ...the PCM Go to step 4 4 Turn the ignition switch OFF 5 Disconnect the TP sensor 3P connector 6 Turn the ignition switch ON II 7 At the wire harness side measure voltage between TP sensor 3P connector...

Page 425: ...tle position with the scan tool or the HDS Intermittent failure system is OK at this time 1 Turn the ignition switch ON II 2 Check the throttle position with the scan tool or the HDS Intermittent fail...

Page 426: ...m Malfunction P1519 Idle Air Control IAC valve DTC P0128 can occasionally set when the hood is opened while the engine is running 1 Turn the ignition switch ON II 2 Make sure the A C off 3 Check the r...

Page 427: ...the fuel pressure see page 11 216 Go to step 5 Repair the fuel supply system 5 Turn the ignition switch OFF 6 Disconnect the primary HO2S Sensor 1 4P connector 7 Turn the ignition switch ON II 8 Chec...

Page 428: ...ge 11 216 Go to step 5 Repair the fuel supply system 5 Turn the ignition switch OFF 6 Disconnect the primary HO2S Sensor 1 4P connector 7 Turn the ignition switch ON II 8 Check the primary HO2S Sensor...

Page 429: ...Sensor 1 and the PCM 4 Turn the ignition switch OFF 5 Disconnect the primary HO2S Sensor 1 4P connector 6 Connect primary HO2S Sensor 1 4P connector terminals No 1 and No 2 with a jumper wire 7 Turn...

Page 430: ...primary HO2S Sensor 1 4P connector 6 Connect primary HO2S Sensor 1 4P connector terminals No 1 and No 2 with a jumper wire 7 Turn the ignition switch ON II 8 Check the primary HO2S Sensor 1 output vo...

Page 431: ...the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on 3 Test drive under these conditions 55 mph 89 km h steady speed Transmission in D4 position 4 Check for a Tempor...

Page 432: ...condary HO2S Sensor 2 and the PCM 4 Turn the ignition switch OFF 5 Disconnect the secondary HO2S Sensor 2 4P connector 6 Turn the ignition switch ON II 7 Check the secondary HO2S Sensor 2 output volta...

Page 433: ...sor 2 and the PCM 4 Turn the ignition switch OFF 5 Disconnect the secondary HO2S Sensor 2 4P connector 6 Turn the ignition switch ON II 7 Check the secondary HO2S Sensor 2 output voltage with the scan...

Page 434: ...r 2 and the PCM 4 Turn the ignition switch OFF 5 Disconnect the secondary HO2S Sensor 2 4P connector 6 Connect secondary HO2S Sensor 2 4P connector terminals No 1 and No 2 with a jumper wire 7 Turn th...

Page 435: ...switch OFF 5 Disconnect the secondary HO2S Sensor 2 4P connector 6 Connect secondary HO2S Sensor 2 4P connector terminals No 1 and No 2 with a jumper wire 7 Turn the ignition switch ON II 8 Check the...

Page 436: ...ark or neutral until the radiator fan comes on 3 Check the secondary HO2S Sensor 2 output voltage at 3 000 rpm with the scan tool or the HDS Replace the secondary HO2S Sensor 2 Intermittent failure sy...

Page 437: ...OFF 4 Disconnect the HO2S primary or secondary Sensor 1 or Sensor 2 4P connector 5 At the HO2S side measure resistance between HO2S 4P connector terminals No 3 and No 4 Go to step 6 Replace the prima...

Page 438: ...und Go to step 13 Repair open in the wire between the primary HO2S Sensor 1 secondary HO2S Sensor 2 and No 6 ECU PCM CRUISE CONTROL 15A fuse 13 Turn the ignition switch OFF 14 Reconnect the HO2S prima...

Page 439: ...connect the HO2S primary or secondary Sensor 1 or Sensor 2 4P connector 5 At the HO2S side measure resistance between HO2S 4P connector terminals No 3 and No 4 Go to step 6 Replace the primary HO2S Se...

Page 440: ...nd Go to step 13 Repair open in the wire between the primary HO2S Sensor 1 secondary HO2S Sensor 2 and No 6 ECU PCM CRUISE CONTROL 15A fuse 13 Turn the ignition switch OFF 14 Reconnect the HO2S primar...

Page 441: ...2 Check these items If the pressure is too high check the fuel pressure regulator and the fuel return line If the pressure is too low check the fuel pump the fuel line the fuel filter and the fuel pre...

Page 442: ...ng with the random misfire DTC s P0107 P0108 P1128 P1129 Manifold Absolute Pressure MAP Sensor P0131 P0132 Primary Heated Oxygen Sensor Primary HO2S P0171 P0172 Fuel System P0335 P0336 Crankshaft Posi...

Page 443: ...freeze data or under various conditions if there was no freeze data 7 Check for a DTC or Temporary DTC with the scan tool or the HDS Go to step 8 Intermittent misfire due to poor contact at the igniti...

Page 444: ...y injector see page 11 177 Go to step 20 20 Turn the ignition switch OFF 21 Disconnect the ignition coil 3P connector from the problem cylinder 22 Turn the ignition switch ON II 23 Measure voltage bet...

Page 445: ...C3 BLU WHT BLU No 4 P0304 C13 YEL BRN No 5 P0305 C12 BLK RED No 6 P0306 C23 WHT BLU BRN WHT Repair short in the wire between the PCM and the ignition coil Go to step 28 28 Connect ignition coil 3P co...

Page 446: ...o to step 35 Go to step 43 35 Turn the ignition switch OFF 36 Disconnect the injector 2P connector from the problem cylinder 37 Measure resistance between injector 2P connector terminals No 1 and No 2...

Page 447: ...N II 46 Measure voltage between injector 2P connector ground Go to step 47 Repair open in the wire between the injector and the PGM FI main relay 47 Turn the ignition switch OFF 48 Check for continuit...

Page 448: ...cover and the ignition 2 After checking and recording the freeze data reset the PCM see page 11 4 If there is no freeze data of misfiring just clear the DTC 3 Start the engine and listen for a clickin...

Page 449: ...no freeze data 18 Check for a DTC or a Temporary DTC with the scan tool or the HDS Go to step 19 Intermittent misfire due to bad contact in the injector connector no misfire at this time Check for poo...

Page 450: ...dy ground and the PCM connector terminal see table PROBLEM CYLINDER DTC PCM TERMINAL WIRE COLOR No 1 P0301 B10 YEL GRN No 2 P0302 B9 RED No 3 P0303 B8 BLU No 4 P0304 B19 YEL No 5 P0305 B18 BLK RED No...

Page 451: ...eck the engine compression see page 6 11 Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM Repair the engine 31 Turn the ignition switc...

Page 452: ...nnections or loose terminals at the injector connectors 42 Determine which cylinder had the misfire Replace the faulty injector see page 11 177 Substitute a known good PCM and recheck see page 11 5 If...

Page 453: ...the PCM and the injector Go to step 49 49 Connect injector 2P connector terminal No 2 to body ground with a jumper wire see table PROBLEM CYLINDER DTC WIRE COLOR No 1 P0301 BRN No 2 P0302 RED No 3 P03...

Page 454: ...connector terminal C22 and body ground Repair short in the wire between the PCM C22 and the C103 knock sensor connector Go to step 7 7 Connect C103 knock sensor connector terminal No 1 to body ground...

Page 455: ...nuity between PCM connector terminal A9 and body ground Repair short in the wire between the PCM A9 and the C103 knock sensor connector Go to step 7 7 Connect C103 knock sensor connector terminal No 1...

Page 456: ...2P connector 5 Measure resistance between CKP sensor 2P connector terminals No 1 and No 2 Go to step 6 Replace the CKP sensor see page 6 61 6 Check for continuity between body ground and CKP sensor 2P...

Page 457: ...e original PCM 1 Reset the PCM see page 11 4 2 Start the engine Go to step 3 Intermittent failure system is OK at this time Check for poor connections or loose terminals at the CKP sensor and the PCM...

Page 458: ...P 9 Measure resistance between PCM connector terminals A12 and A24 Go to step 10 Repair open in the wire between the PCM A12 A24 and the CKP sensor 10 Check for continuity between body ground and PCM...

Page 459: ...the CMP sensor A B and at the PCM 3 Turn the ignition switch OFF 4 Disconnect the CMP sensor A B 4P connector 5 Measure resistance between the terminals of the indicated sensor see table CMP A P0340 1...

Page 460: ...UP 7 5A fuse in the passenger s under dash fuse relay box is removed and the engine is started MIL will come on and the PCM will store DTC P0560 1 Reset the PCM see page 11 4 2 Start the engine Go to...

Page 461: ...box 1 Reset the PCM see page 11 4 2 Start the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on then let it idle 3 Test drive with the transmission in...

Page 462: ...Intermittent failure system is OK at this time 1 Reset the PCM see page 11 4 2 Start the engine 3 Turn on the headlights Go to step 4 Intermittent failure system is OK at this time Check for poor con...

Page 463: ...tom indication goes away replace the original PCM 1 Reset the PCM see page 11 4 2 Start the engine 3 Turn on the headlights Go to step 4 Intermittent failure system is OK at this time Check for poor c...

Page 464: ...Go to step 4 Intermittent failure system is OK at this time Check for poor connections or loose terminals at the ELD and the PCM 4 Turn the ignition switch and headlights OFF 5 Disconnect the ELD 3P c...

Page 465: ...30 and the ELD 12 Check for continuity between ELD 3P connector terminal No 2 and body ground Reconnect the ELD 3P connector and PCM connector A 31P Go to step 13 Repair open in the wire between the E...

Page 466: ...between body ground and ELD 3P connector terminal No 1 Go to step 8 Check the No 6 ECU PCM CRUISE CONTROL 15A fuse in the driver s under dash fuse relay box If the fuse is OK repair open in the wire b...

Page 467: ...inals A26 and E19 turn the headlights on low Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM Replace ELD 1 Reset the PCM see page 11...

Page 468: ...t PCM connector C 31P 9 Measure resistance between the terminals of the indicated sensor on the PCM connector see table TDC1 P1361 1 C20 GRN P1362 2 C21 RED TDC2 P1366 3 C29 YEL P1367 4 C30 BLK Go to...

Page 469: ...inals at the TDC1 TDC2 sensor and the PCM 3 Turn the ignition switch OFF 4 Disconnect the TDC1 TDC2 sensor 4P connector 5 Measure resistance between the terminals of indicated sensor see table TDC1 P1...

Page 470: ...heck see page 11 5 If the symptom indication goes away replace the original PCM 1 Reset the PCM see page 11 4 2 Go to step 3 Check for poor connections or loose terminals at the ABS TCS control unit a...

Page 471: ...t and recheck If the symptom indication goes away replace the original ABS TCS control unit Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the origin...

Page 472: ...ptom indication goes away replace the original ABS TCS control unit Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM 1 Reset the PCM s...

Page 473: ...e original ABS TCS control unit Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM 1 Reset the PCM see page 11 4 2 Start the engine and...

Page 474: ...ssenger s under dash fuse relay box Intermittent failure system is OK at this time A low battery can cause this problem Ask the customer if the engine had to be jump started recently 1 Reset the PCM s...

Page 475: ...A18 and the gauge assembly If the MIL is always off go to step 6 But if the MIL sometimes works normally first check for these problems A loose No 9 BACK UP LIGHT INSTRUMENT LIGHT 7 5A fuse in the dri...

Page 476: ...auge assembly Also check for a blown MIL bulb 11 Turn the ignition switch OFF 12 Inspect the ACGS 15A fuse in the under hood fuse relay box Go to step 13 Check for these problems A short in the wire b...

Page 477: ...ure voltage between body ground and PCM connector terminals B1 and B9 individually Go to step 20 Check for these problems An open in the wire s between the PGM FI main relay and PCM connector terminal...

Page 478: ...the ignition switch OFF 27 Disconnect PCM connector A 32P 28 Turn the ignition switch ON II Repair short in the wire between the gauge assembly and the PCM A18 Substitute a known good PCM and recheck...

Page 479: ...the PCM A31 and the manifold absolute pressure MAP sensor An intermittent short in the wire between the PCM A30 and the throttle position TP sensor or the Exhaust Gas Recirculation EGR valve position...

Page 480: ...f these sensors one at a time and check for continuity between body ground and PCM connector terminals A30 A31 and E6 individually Manifold Absolute Pressure MAP sensor Exhaust Gas Recirculation EGR v...

Page 481: ...16 and body ground Go to step 26 Go to step 23 23 Turn the ignition switch OFF 24 Disconnect PCM connector E 31P 25 Check for continuity between PCM connector terminal E16 and body ground Repair short...

Page 482: ...p 3 Repair open in the wire between DLC terminal No 16 and the ACGS 15A fuse in the under hood fuse relay box 3 Measure voltage between DLC terminal No 4 and No 16 Go to step 4 Repair open in the wire...

Page 483: ...check see page 11 5 If the symptom indication goes away with a known good PCM replace the original PCM Repair open in the wire between DLC terminal No 7 and the PCM A21 10 Turn the ignition switch OFF...

Page 484: ...hood fuse relay box 3 Measure voltage between DLC terminals No 4 and No 16 Go to step 4 Repair open in the wire between DLC terminal No 4 and G501 4 Measure voltage between DLC terminals No 5 and No 1...

Page 485: ...check see page 11 5 If the symptom indication goes away with a known good PCM replace the original PCM Repair open in the wire between DLC terminal No 7 and the PCM E27 10 Turn the ignition switch OFF...

Page 486: ...s and the intake manifold see page 9 4 3 Disconnect the connectors from the injectors A 4 Disconnect the vacuum hose and fuel return hose from the fuel pressure regulator B Place a rag or a shop towel...

Page 487: ...e intake manifold 12 Install the fuel rail in the intake manifold 13 Install and tighten the bolts 14 Connect the vacuum hose and fuel return hose to the fuel pressure regulator 15 Install the connect...

Page 488: ...15 2 Remove the intake manifold covers and the intake manifold see page 9 4 3 Disconnect the connectors from the injectors A 4 Remove the retainer bolts B from the fuel rails C and harness holders D t...

Page 489: ...ss them into the intake manifold 11 Install the fuel injectors and fuel rails into the intake manifold 12 Install and tighten the retainer bolts 13 Install the connectors on the injectors 14 Install t...

Page 490: ...Tools 93750 or equivalent commercially available 1 Disconnect the primary HO2S 4P connector A then remove the primary HO2S B 2 Install the primary HO2S in the reverse order of removal O2 sensor wrench...

Page 491: ...182 Idle Control System Component Location Index IDLE AIR CONTROL IAC VALVE POWER STEERING PRESSURE PSP SWITCH Troubleshooting page 11 184 Troubleshooting page 11 196 The illustration shows 99 00 Mode...

Page 492: ...less than 680 rpm go to step 3 if it s 780 rpm or higher go to step 4 3 Disconnect the IAC valve 3P connector Adjust the idle speed see page 11 201 If the idle speed will not adjust properly clean th...

Page 493: ...Turn the ignition switch ON II 6 Measure voltage between IAC valve 3P connector terminal No 2 and body ground Go to step 7 Repair open in the wire between the IAC valve and the PGM FI main relay 7 Tur...

Page 494: ...dy ground Go to step 13 Repair open in the wire between the IAC valve and the PCM B23 13 Remove the jumper wire from the IAC valve 3P connector then reconnect the IAC valve 3P connector 14 Turn the ig...

Page 495: ...switch ON II 6 Measure voltage between IAC valve 3P connector terminal No 2 and body ground Go to step 7 Repair open in the wire between the IAC valve and the PGM FI main relay 7 Turn the ignition swi...

Page 496: ...the wire between the IAC valve and the PCM B23 13 Remove the jumper wire from the IAC valve 3P connector then reconnect the IAC valve 3P connector 14 Turn the ignition switch ON II 15 Measure voltage...

Page 497: ...n PCM connector terminals A27 and B20 Go to step 5 Go to step 12 5 Turn the ignition switch OFF 6 Reconnect the A C pressure switch 4P connector 7 Turn the ignition switch ON II 8 Momentarily connect...

Page 498: ...a jumper wire several times NOTE The under hood fuse relay box 16P you unbolt and invert the fuse box leave the upper cover on to prevent short circuits Repair open in the wire between the PCM A17 an...

Page 499: ...ep 5 Go to step 12 5 Turn the ignition switch OFF 6 Reconnect the A C pressure switch 4P connector 7 Turn the ignition switch ON II 8 Momentarily connect PCM connector terminals A26 and E12 with a jum...

Page 500: ...per wire several times NOTE The under hood fuse relay box 16P connector is on the bottom of the fuse box When you unbolt and invert the fuse box leave the upper cover on to prevent short circuits Repa...

Page 501: ...Park or neutral until the radiator fan comes on then let it idle 7 Measure voltage between PCM connector terminals B20 and C5 The alternator FR signal is OK Go to step 8 8 Turn the ignition switch OF...

Page 502: ...between PCM connector terminals A19 and A26 Go to step 4 Go to step 13 4 Turn the ignition switch OFF 5 Reconnect the alternator 4P connector 6 Start the engine Hold the engine at 3 000 rpm with no lo...

Page 503: ...9 Test the alternator see step 1 on page 4 24 Repair open in the wire between the PCM A19 and the alternator 13 Turn the ignition switch OFF 14 Disconnect PCM connector A 31P 15 Check for continuity b...

Page 504: ...TARTER SIGNAL 7 5A fuse Repair short in the wire between the PCM A24 and the No 13 STARTER SIGNAL 7 5A fuse or the PGM FI main relay Replace the No 13 STARTER SIGNAL 7 5A fuse 1 Shift the transmission...

Page 505: ...Turn the ignition switch OFF 7 Disconnect the PSP switch 2P connector 8 Turn the ignition switch ON II 9 At the harness side connect PSP switch 2P connector terminals No 1 and No 2 with a jumper wire...

Page 506: ...titute a known good PCM and recheck see page 11 5 If voltage is normal replace the original PCM 1 Turn the ignition switch ON II 2 Measure voltage between PCM connector terminals A26 and E20 Go to ste...

Page 507: ...tween the PSP switch and PCM E20 Repair open in the wire between the PSP switch and G201 13 Turn the ignition switch OFF 14 Disconnect the PSP switch 2P connector 15 Turn the ignition switch ON II 16...

Page 508: ...ls A32 and B20 with the brake pedal pressed The brake pedal position switch signal is OK Repair open in the wire between the PCM A32 and the brake pedal position switch 4 Inspect the STOP 20A fuse in...

Page 509: ...e brake pedal pressed The brake pedal position switch signal is OK Repair open in the wire between the PCM E9 and the brake pedal position switch 4 Inspect the STOP 20A fuse in the under hood fuse rel...

Page 510: ...art the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on then let it idle 4 Check the idle speed with no load conditions headlights blower fan rear w...

Page 511: ...of the connectors from the under hood fuse relay box Disconnect any of the connectors from the driver s passenger s under dash fuse relay box Disconnect the connector between the engine wire harness...

Page 512: ...P FUEL FEED LINE FUEL FILL CAP FUEL TANK FUEL VAPOR LINE FUEL PRESSURE REGULATOR FUEL FILTER FUEL GAUGE SENDING UNIT FUEL RETURN LINE FUEL RAIL cont d Test page 11 218 Replacement page 11 230 Replacem...

Page 513: ...CAP FUEL TANK FUEL VAPOR LINE FUEL PRESSURE REGULATOR FUEL FILTER FUEL GAUGE SENDING UNIT FUEL RETURN LINE FUEL RAIL PGM FI MAIN RELAY Test page 11 218 Replacement page 11 230 Replacement page 11 232...

Page 514: ...tep 3 11 234 3 4 Reset the PCM see page 11 4 5 Do the PCM idle learn procedure see page 11 202 If the fuel gauge sending unit OK Performance Problem NOTE Because it requires 174 miles 280 km of drivin...

Page 515: ...Go to step 4 Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM 4 Turn the ignition switch OFF 5 Remove the rear seats and carpet and th...

Page 516: ...und Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM Go to step 14 14 Turn the ignition switch OFF 15 Disconnect the gauge assembly co...

Page 517: ...he fuel tank unit 5P connector 6 Measure resistance between fuel tank unit 5P connector terminals No 1 and No 2 Go to step 7 Replace the fuel gauge sending unit see page 11 234 7 Check for continuity...

Page 518: ...G S 15A fuse in the under hood fuse relay box Repair short in the wire between the PGM FI main relay and the ACG S 15A fuse Repair open in the wire between the PGM FI main relay and the ACG S 15A fuse...

Page 519: ...h fuse relay box Repair short in the wire between the PGM FI main relay and the No 13 STARTER SIGNAL 7 5A fuse Repair open in the wire between the PGM FI main relay and the No 13 STARTER SIGNAL 7 5A 1...

Page 520: ...o PGM FI main relay 7P connector terminal No 2 and connect PGM FI main relay 7P connector terminal No 1 to ground Then check for continuity between PGM FI main relay 7P connector terminals No 5 and No...

Page 521: ...r a blown ACG S 15A fuse in the under hood fuse relay box Repair short in the wire between the PGM FI main relay and the ACG S 15A fuse Repair open in the wire between the PGM FI main relay and the AC...

Page 522: ...GM FI main relay and the No 13 STARTER SIGNAL 7 5A 10 Turn the ignition switch OFF 11 Disconnect PCM connector E 31P 12 Check for continuity between PGM FI main relay 7P connector terminal No 1 and th...

Page 523: ...nector terminal No 1 to ground Then check for continuity between PGM FI main relay 7P connector terminals No 5 and No 4 NOTE Use the terminal numbers shown Ignore the terminal numbers molded into the...

Page 524: ...he navigation system if equipped then write down the frequencies for the radio s preset buttons 2 Disconnect the negative cable from the battery 3 Remove the fuel fill cap 4 Place a wrench on the fuel...

Page 525: ...damper from its fitting and attach the fuel pressure gauge attachment 8 Attach the fuel pressure gauge 9 99 01 models Disconnect the vacuum hose A of the fuel pressure regulator and pinch it closed w...

Page 526: ...lems If the pressure is too low check for a clogged fuel filter and for leaks in the fuel lines If the pressure is too high check for a pinched or clogged fuel return hose or line Fuel rail restrictio...

Page 527: ...he fuel pump does not make noise check as follows 1 Remove the rear seats and carpet 2 Remove the access panel A from the floor 3 Turn the ignition switch OFF then disconnect the fuel pump 5P connecto...

Page 528: ...e Inspection 37 N m 3 8 kgf m 27 lbf ft 22 N m 2 2 kgf m 18 lbf ft 37 N m 3 8 kgf m 27 lbf ft 22 N m 2 2 kgf m 18 lbf ft Check the fuel system lines hoses and fuel filter for damage leaks and deterior...

Page 529: ...02 04 models 11 220 Fuel Supply System Fuel Line Inspection cont d 37 N m 3 8 kgf m 27 lbf ft 22 N m 2 2 kgf m 18 lbf ft...

Page 530: ...the line at these joints To FUEL PRESSURE REGULATOR To EVAPORATIVE EMISSION EVAP PURGE CONTROL SOLENOID VALVE B B B A A B B B B B 10 15 mm 0 39 0 59 in A B Check all hose clamps and retighten if nece...

Page 531: ...B B B B B B B B B A A B To FUEL PRESSURE REGULATOR To EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE Do not disconnect the hose from the line at these joints 10 15 mm 0 39 0 59 in A B Check all hose...

Page 532: ...ery electrolyte Replace them if they came into contact with electrolyte or something similar When connecting or disconnecting the fuel tubes A and quick connect fittings B be careful not to bend or tw...

Page 533: ...e the line D or other parts Do not use tools If the connector does not move keep the retainer tabs pressed down and alternately pull and push the connector until it comes off easily Do not remove the...

Page 534: ...Insert a new retainer A into the connector B if the retainer is damaged or after replacing the fuel pump replacing the fuel filter replacing the fuel feed line replacing the fuel return line removing...

Page 535: ...onto the line until both retainer pawls lock with a clicking sound NOTE If it is hard to connect put a small amount of new engine oil on the line end 5 Make sure the connection is secure and that the...

Page 536: ...the fuel pressure regulator apply clean engine oil to the O ring and assemble it into its proper position taking care not to damage the O ring 7 Turn the fuel pressure regulator A counterclockwise to...

Page 537: ...regulator D 4 Apply clean engine oil to a new O ring E and carefully install it into its proper position 5 Install the fuel pressure regulator in the fuel joint Turn it by hand until it stops NOTE Re...

Page 538: ...art of the suction filter C When installing the fuel gauge sending unit D make sure the connection is secure and the connector is firmly locked into place Be careful not to bend or twist it excessivel...

Page 539: ...and the suction filter F is firmly connected to the fuel pump G 10 Check these items before installing the fuel tank unit When connecting the wire harness make sure the connection is secure and the co...

Page 540: ...oline draw the fuel from the fuel tank 4 Disconnect the fuel vapor hoses and quick connect fittings Disconnect the hoses Slide back the clamps then twist the hoses as you pull to avoid damaging them 5...

Page 541: ...gasoline draw the fuel from the fuel tank 4 Disconnect the fuel tank vapor vent tube fuel vapor hoses and quick connect fittings Disconnect the hoses Slide back the clamps then twist the hoses as you...

Page 542: ...ntinuity check for an open in the BLK wire or a poor ground G551 8 Measure voltage between gauge assembly 16P connector terminal No 11 and body ground with the ignition switch ON II There should be be...

Page 543: ...LL positions If you do not get the following readings replace the fuel gauge sending unit Float Position E LOW 1 2 F Resistance 10 Before you install the fuel tank unit check these items When connecti...

Page 544: ...at at the E EMPTY position If the low fuel indicator is on go to step 3 If the low fuel indicator is not on refer to the low fuel indicator circuit diagram see page 22 96 and check the circuit 3 Move...

Page 545: ...CABLE INTAKE AIR BYPASS CONTROL THERMAL VALVE AIR CLEANER Test page 11 237 Cleaning page 11 237 Removal Installation page 11 243 Disassembly Reassembly page 11 245 Adjustment page 11 242 Test page 11...

Page 546: ...e is excessive play in the throttle valve shaft or any binding in the throttle valve at the fully closed position replace the throttle body If the throttle valve and shaft are OK go to step 3 3 Connec...

Page 547: ...ading changes go to step 4 If the vacuum reading does not change check for these problems Misrouted leaking broken or clogged intake air bypass control thermal system vacuum lines A cracked or damage...

Page 548: ...he shaft for binding or sticking If it is OK replace the air cleaner housing 3 Start the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on 4 Check the...

Page 549: ...ons 2 Remove the cable clamp A from the air cleaner housing cover B 3 Remove the battery negative terminal C and screw D 4 Remove the cover E 5 Remove the air cleaner element F from the air cleaner ho...

Page 550: ...2 lbf ft 2 9 N m 0 3 kgf m 2 2 lbf ft 1 Drain the coolant see page 10 13 2 Remove the air cleaner housing 3 Remove the cover A and the radiator B from the air cleaner housing C 4 Install the parts in...

Page 551: ...3 8 1 2 in 3 If free play is not within specs 10 12 mm 3 8 1 2 in loosen the locknut B turn the adjusting nut C until the free play is as specified then retighten the locknut 4 With the cable properl...

Page 552: ...SKET GASKET CRUISE CONTROL CABLE GASKET MAP SENSOR THROTTLE CABLE CRUISE CONTROL CABLE 22 N m 2 2 kgf m 16 lbf ft TP SENSOR SPACER NOTE Do not adjust the throttle stop screw After reassembly adjust th...

Page 553: ...02 04 models 11 244 Intake Air System Throttle Body Removal Installation cont d GASKET MAP SENSOR THROTTLE CABLE CRUISE CONTROL CABLE 22 N m 2 2 kgf m 16 lbf ft TP SENSOR SPACER Replace...

Page 554: ...MAP SENSOR IDLE ADJUSTING SCREW O RING IAC VALVE 3 5 N m 0 35 kgf m 2 5 lbf ft O RING TP SENSOR O RING SPACER 2 1 N m 0 21 kgf m 1 5 lbf ft MAP SENSOR O RING O RING IDLE ADJUSTING SCREW IAC VALVE O R...

Page 555: ...the radiator fan comes on 3 Drive for about 10 minutes without stopping on a highway or freeway Your speed can vary 4 With the transmission in D4 D5 position drive at a steady speed between 50 62 mph...

Page 556: ...system is OK at this time Clean the intake manifold EGR port with caburetor cleaner Clean the passage inside the EGR valve with carburetor cleaner or replace the EGR valve NOTE Information marked with...

Page 557: ...Measure voltage between EGR valve 6P connector terminals No 2 and No 3 Go to step 13 Go to step 12 12 Measure voltage between PCM connector terminals C18 and C28 Repair open in the wire between the E...

Page 558: ...connector terminal C6 and body ground Repair short in the wire between the EGR valve and PCM C6 Repair open in the wire between the EGR valve and PCM C6 21 Turn the ignition switch OFF 22 Disconnect t...

Page 559: ...nal No 4 to body ground with a jumper wire 29 Check for continuity between PCM connector terminal B7 and body ground Go to step 30 Repair open in the wire between the EGR valve and the PCM B7 30 Disco...

Page 560: ...witch OFF 6 Disconnect the EGR valve 6P connector 7 Start the engine and let it idle 8 Measure voltage between EGR valve 6P connector terminals No 4 and No 6 Substitute a known good PCM and recheck se...

Page 561: ...Reconnect the EGR valve connector 17 Turn the ignition switch ON II 18 Measure voltage between PCM connector terminals A16 and A28 Go to step 21 Go to step 19 19 Turn the ignition switch OFF 20 Check...

Page 562: ...he ignition switch OFF 26 Disconnect PCM connector B 24P 27 Check for continuity between PCM connector terminal B3 and body ground Repair short in the wire between the EGR valve and the PCM B3 Go to s...

Page 563: ...R valve 6P connector 31 Check for continuity between EGR valve 6P connector terminal No 6 and body ground Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away repl...

Page 564: ...or loose terminals at the EGR valve and the PCM 3 Turn the ignition switch OFF 4 Disconnect the EGR valve 6P connector 5 Turn the ignition switch ON II 6 Measure voltage between EGR valve 6P connector...

Page 565: ...valve and the PCM 3 Turn the ignition switch OFF 4 Disconnect the EGR valve 6P connector 5 Turn the ignition switch ON II 6 Measure voltage between EGR valve 6P connector terminals No 2 and No 3 Repl...

Page 566: ...cover see page 9 4 2 Check the PCV valve A hoses B and connections for leaks or restrictions 3 At idle make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and i...

Page 567: ...RATIVE EMISSION EVAP CANISTER VENT SHUT VALVE EVAPORATIVE EMISSION EVAP CONTROL CANISTER EVAPORATIVE EMISSION EVAP TWO WAY VALVE Troubleshooting step 3 on page 11 269 step 1 on page 11 282 Troubleshoo...

Page 568: ...ATIVE EMISSION EVAP CANISTER EVAPORATIVE EMISSION EVAP TWO WAY VALVE FUEL TANK VAPOR CONTROL VALVE Troubleshooting step 3 on page 11 274 step 1 on page 11 287 Troubleshooting page 11 262 Troubleshooti...

Page 569: ...R VENT SHUT VALVE EVAPORATIVE EMISSION EVAP CANISTER EVAPORATIVE EMISSION EVAP TWO WAY VALVE FUEL TANK VAPOR CONTROL VALVE Troubleshooting step 3 on page 11 278 step 1 on page 11 292 Troubleshooting p...

Page 570: ...the EVAP two way valve and the FTP sensor at the EVAP two way valve end 6 Connect a vacuum pump to the open end of the hose 7 Turn the ignition switch ON II 8 Monitor FTP sensor voltage with the HDS...

Page 571: ...EVAP two way valve end 6 Connect a vacuum pump to the open end of the hose 7 Turn the ignition switch ON II 8 Monitor the FTP sensor voltage with the HDS or measure voltage between PCM connector term...

Page 572: ...h ON II 5 Monitor FTP sensor voltage with the HDS or measure voltage between body ground and PCM connector terminal A29 Intermittent failure system is OK at this time Check for poor connections or loo...

Page 573: ...d PCM and recheck see page 11 5 If normal voltage is indicated replace the original PCM 1 Check the vacuum lines at the FTP sensor for misrouting leakage breakage and clogging Go to step 2 Repair or r...

Page 574: ...the FTP sensor and the PCM E6 11 Measure voltage between FTP sensor 3P connector terminals No 2 and No 3 Replace the FTP sensor Go to step 12 12 Turn the ignition switch OFF 13 Disconnect PCM connecto...

Page 575: ...Turn the ignition switch ON II 5 Monitor FTP sensor voltage with the HDS or measure voltage between body ground and PCM connector terminal A29 Intermittent failure system is OK at this time Check for...

Page 576: ...ndicated replace the original PCM 1 Check the vacuum lines of the FTP sensor for misrouting leakage breakage and clogging Go to step 2 Repair or replace vacuum lines as necessary 2 Reset the PCM see p...

Page 577: ...terminals No 1 and No 2 Go to step 11 Repair open in the wire between the FTP sensor and the PCM E7 11 Measure voltage between FTP sensor 3P connector terminals No 2 and No 3 Replace the FTP sensor Go...

Page 578: ...refully to ensure the integrity of the system and to confirm the cause of the problem or code NOTE Fresh fuel has a higher volatility that will create greater pressure vacuum The optimum condition for...

Page 579: ...epair short in the wire between the EVAP purge control solenoid valve and the PCM A6 Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM...

Page 580: ...A and the O rings B Repair open in the wire between the EVAP bypass solenoid valve and No 6 ECU PCM CRUISE CONTROL 15A fuse 20 Plug the upper port A of the EVAP two way valve 21 While monitoring the...

Page 581: ...nition switch OFF 26 Disconnect the EVAP canister vent valve 2P connector 27 Check for continuity between EVAP canister vent shut valve 2P connector terminal No 2 and body ground Go to step 28 Replace...

Page 582: ...r DTC P1456 NOTE If DTC P0461 is stored at the same time as DTC P1456 troubleshoot DTC P0461 first then recheck for DTC P1456 This is a two trip code once cleared it cannot be reproduced in one trip A...

Page 583: ...to step 6 6 Turn the ignition switch OFF 7 Disconnect the EVAP canister purge valve 2P connector 8 Check for continuity between EVAP canister purge valve 2P connector terminal No 1 and body ground Go...

Page 584: ...ep 20 15 Turn the ignition switch OFF 16 Disconnect the EVAP bypass solenoid valve 2P connector 17 Check for continuity continuity between EVAP bypass solenoid valve 2P connector terminal No 2 and bod...

Page 585: ...om the EVAP bypass solenoid valve EVAP two way valve FTP sensor or O rings 22 Disconnect the vacuum hose from the EVAP canister filter A and connect a vacuum pump to the hose 23 Turn the ignition swit...

Page 586: ...lve 31 Tighten the fuel cap 3 clicks then monitor the fuel tank pressure readings with the HDS 32 Start the engine Let the engine idle for 5 minutes 33 Check the FTP sensor readings Substitute a known...

Page 587: ...roubleshooting procedures carefully to ensure the integrity of the system and to confirm the cause of the problem or code NOTE Fresh fuel has a higher volatility that will create greater pressure vacu...

Page 588: ...ter purge valve and the PCM A6 Substitute a known good PCM and recheck see page 11 5 If the symptom indication goes away replace the original PCM 11 Disconnect both vacuum hoses from the EVAP two way...

Page 589: ...the EVAP bypass solenoid valve A and the O rings B Repair open in the wire between the EVAP bypass solenoid valve and No 6 ECU PCM CRUISE CONTROL 15A fuse 20 Plug the upper port A of the EVAP two way...

Page 590: ...sconnect the EVAP canister vent valve 2P connector 27 Check for continuity between EVAP canister vent shut valve 2P connector terminal No 2 and body ground Go to step 28 Replace the EVAP canister vent...

Page 591: ...edures Excessive pressure vacuum would damage the EVAP components or cause eventual fuel tank system failure Vacuum pump gauge 0 30 in Hg A973X 041 XXXXX NOTE If DTC P0461 is stored at the same time a...

Page 592: ...lve 2P connector 7 Check for continuity between EVAP purge control solenoid valve 2P connector terminal No 2 and body ground Go to step 8 Repair open in the wire between the EVAP purge control solenoi...

Page 593: ...bypass solenoid valve 2P connector terminal No 2 and body ground Go to step 16 Replace the EVAP bypass solenoid valve A and O rings B 16 Disconnect PCM connector A 32P 17 Check for continuity between...

Page 594: ...e EVAP canister vent shut valve 2P connector 24 Check for continuity between EVAP canister vent shut valve 2P connector terminal No 2 and body ground Go to step 25 Repair open in the wire between the...

Page 595: ...perature is still above 95 F 35 C and your vacuum pump does not have a leak 33 Check the voltage for 20 seconds Inspect the EVAP canister vent shut valve line and connections Go to step 34 34 Turn the...

Page 596: ...e see page 11 89 Follow these troubleshooting procedures carefully to ensure the integrity of the system and to confirm the cause of the problem or code NOTE Fresh fuel has a high volatility that crea...

Page 597: ...CM CRUISE CONTROL 15A fuse 10 Disconnect the vacuum hose from the EVAP two way valve A and connect a vacuum pump to the hose 11 Turn the ignition switch ON II 12 Apply vacuum to the hose The EVAP bypa...

Page 598: ...e from the EVAP canister vent filter A and connect a vacuum pump to the hose 19 Turn the EVAP canister vent shut valve on with the HDS or connect PCM connector terminal E22 to body ground with a jumpe...

Page 599: ...three way T fittings A into the hose from the EVAP canister to the EVAP two way valve Connect the FTP sensor to one of the T fittings and the vacuum pump to the other 29 Remove the vent hose from the...

Page 600: ...and connections are OK replace the fuel tank vapor control valve Go to step 40 40 Turn the ignition switch OFF 41 Disconnect the purge line hose A from the canister at the metal line and plug the hose...

Page 601: ...setting the readiness code see page 11 89 Follow these troubleshooting procedures carefully to ensure the integrity of the system and to confirm the cause of the problem or code NOTE Fresh fuel has a...

Page 602: ...fuse 10 Disconnect the vacuum hose from the EVAP two way valve A and connect a vacuum pump to the hose 11 Turn the ignition switch ON II 12 Apply vacuum to the hose EVAP bypass solenoid valve EVAP tw...

Page 603: ...sconnect the vacuum hose from the EVAP canister vent filter A and connect a vacuum pump to the hose 19 Turn the EVAP canister vent shut valve on with the HDS or connect PCM connector terminal A4 to bo...

Page 604: ...to the hose from the EVAP canister to the EVAP two way valve Connect the FTP sensor to one of the T fittings and the vacuum pump to the other 29 Remove the vent hose from the EVAP canister vent shut v...

Page 605: ...eas If the line and connections are OK replace the fuel tank vapor control valve Go to step 40 40 Turn the ignition switch OFF 41 Disconnect the purge line hose A from the canister at the metal line a...

Page 606: ...e momentarily at 0 8 2 1 kPa 0 2 0 6 in Hg 6 16 mmHg If the vacuum stabilizes valve opens below 0 8 kPa 0 2 in Hg 0 6 mm Hg or above 2 1 kPa 0 6 in Hg 16 mmHg install a new valve and retest 4 Move the...

Page 607: ...to relieve the fuel tank pressure then reinstall the cap 3 Remove the bolts and fuel tank vapor control valve cover A 4 Remove the bolts A 5 Disconnect the fuel tank vapor recirculation tube A and con...

Page 608: ...tank vapor control valve cover A 4 Remove the bolts A 5 Disconnect the fuel tank vapor signal tube A 6 Disconnect the vacuum hose A from the EVAP canister B and then plug the ports C 7 Disconnect the...

Page 609: ...uel then check for fuel in the EVAP two way valve A and fuel tank vapor recirculation hose B NOTE At either location tiny droplets of fuel are normal If fuel runs out of the hoses at either location r...

Page 610: ...nt A 9 8 N m 1 0 kgf m 7 2 lbf ft A 9 8 N m 1 0 kgf m 7 2 lbf ft A 1 Remove the fuel tank vapor control valve cover A 2 Remove the bolts A 3 Remove the fuel tank vapor control valve A 4 Install the fu...

Page 611: ...color coding Related components are located in the steering column front console dashboard dashboard lower panel in the dashboard above the glove box in the front seats and around the floor Do not us...

Page 612: ...Transaxle 4 speed Automatic Transmission 14 1 5 speed Automatic Transmission 14 245 Driveline Axle 16 1 03 07 29 09 29 07 61S0X050_140_0002...

Page 613: ...03 07 29 09 29 07 61S0X050_140_0003...

Page 614: ...ck System Circuit 14 179 Key Interlock System Circuit 14 182 Control Unit Input Test 14 184 Key Interlock Solenoid Switch Test 14 185 Shift Lock Solenoid Test 14 185 Shift Lock Solenoid Replacement 14...

Page 615: ...Hose Adapter 4 07SAZ 001000A Backprobe Set 2 07XAA 001030A Engine Support Fixture 1 07XAJ S0KA100 Preload Inspection Tool 1 07ZAE PRP0100 Clutch Compressor Attachment 1 07406 0020400 or 07406 0020401...

Page 616: ...fuel and emissions DTCs A T DTCs and freeze data 4 If there is a fuel and emissions DTC first check the fuel and emissions system as indicated by the DTC except for DTC P0700 DTC P0700 means there is...

Page 617: ...ong and short blinks One long blink equals 10 short blinks Add the long and short blinks together to determine the code 3 Record all fuel and emissions DTCs and A T DTCs 4 If there is a fuel and emiss...

Page 618: ...ide until it touches the end of the wire terminal 5 If you cannot get to the wire side of the connector or the wire side is sealed disconnect the connector and use the tester probe to probe the connec...

Page 619: ...the No 13 fuse in the passenger s under dash fuse relay box for more than 10 seconds If you do you need to do the following Get the customer s radio and navigation if equipped anti theft code and writ...

Page 620: ...lenoid valve C see page 14 79 P1705 5 Blinks ON A T gear position switch short to ground see page 14 81 P1706 6 OFF ON A T gear position switch open see page 14 84 P1738 25 OFF OFF 2nd clutch pressure...

Page 621: ...ON Transmission range switch short to ground see page 14 108 P1706 6 OFF ON Transmission range switch open see page 14 111 P1738 25 OFF OFF 2nd clutch pressure switch see page 14 113 P1739 26 OFF OFF...

Page 622: ...level Shift cable broken or out of adjustment Shift cable worn ATF pump worn or binding Regulator valve stuck or spring worn ATF strainer clogged Mainshaft worn or damaged Final gears worn or damaged...

Page 623: ...d in R 1 2 3 4 5 6 Shift fork shaft stuck Modulator valve defective Reverse Clutch Pressure Control CPC valve defective 4th accumulator defective 4th clutch defective Reverse gears worn or damaged Che...

Page 624: ...Check the spring retainer for wear and damage Inspect the clutch end plate to top disc clearance If the clearance is out of tolerance inspect the clutch discs and plates for wear and damage If the di...

Page 625: ...ission mounts Check the ATF level and check the ATF cooler lines for leakage and loose connections If necessary flush the ATF cooler lines Vehicle moves in N 1 2 3 4 5 6 7 8 9 Excessive ATF Foreign ma...

Page 626: ...ance inspect the clutch discs and plates for wear and damage If the discs and plates are worn or damaged replace them as a set If they are OK adjust the clutch end plate clearance Late shift after shi...

Page 627: ...downshifts 1 2 3 4 A T clutch pressure control solenoid valves A and B defective CPC valve A defective CPC valve B defective Foreign material in separator plate orifice Check the D4 indicator and chec...

Page 628: ...check the shift solenoid valve for seizure Check the 3rd and 4th clutch pressures If the ATF strainer is clogged with particles of steel or aluminum inspect the ATF pump If the ATF pump is OK and no...

Page 629: ...P 1 2 3 Shift cable broken or out of adjustment Joint in shift cable and transmission or body worn Park mechanism defective Check for a loose shift cable at the shift lever and the transmission contro...

Page 630: ...haft speed sensor defective Torque converter clutch piston defective Torque converter check valve defective Lock up shift valve defective Lock up control valve defective Check the D4 indicator and che...

Page 631: ...ey are bolted to the torque converter housing The main valve body contains the manual valve the modulator valve the shift valve C the shift valve D the shift valve E the servo control valve the torque...

Page 632: ...rough 3rd 2nd and 1st on deceleration to stop The lock up mechanism operates in 3rd and 4th gear D3 DRIVE 1st through 3rd Used for rapid acceleration at highway speeds and general driving up hill and...

Page 633: ...nd is located at the middle of the secondary shaft The 1st clutch is joined back to back to the 2nd clutch The 1st clutch is supplied hydraulic pressure by its ATF feed pipe within the secondary shaft...

Page 634: ...LATE FINAL DRIVE GEAR COUNTERSHAFT 3RD GEAR COUNTERSHAFT 1ST GEAR DIFFERENTIAL ASSEMBLY FINAL DRIVEN GEAR SECONDARY SHAFT 1ST GEAR 1ST CLUTCH 2ND CLUTCH SECONDARY SHAFT 2ND GEAR SECONDARY SHAFT IDLER...

Page 635: ...and park gear are splined with the countershaft and rotate with the countershaft The 4th gear and reverse gear rotate freely from the countershaft The reverse selector engages the 4th gear or the reve...

Page 636: ...the park gear Engine power transmitted from the torque converter drives the mainshaft idler gear the countershaft idler gear and the secondary shaft idler gear but hydraulic pressure is not applied to...

Page 637: ...is automatically selected from the 1st 2nd 3rd and 4th gears according to conditions such as the balance between the throttle opening engine loading and vehicle speed Hydraulic pressure is applied to...

Page 638: ...AR COUNTERSHAFT IDLER GEAR Hydraulic pressure is applied to the 2nd clutch then the 2nd clutch engages the secondary shaft 2nd gear with the secondary shaft The mainshaft idler gear drives the seconda...

Page 639: ...DRIVEN GEAR FINAL DRIVE GEAR MAINSHAFT 3RD GEAR 3RD CLUTCH COUNTERSHAFT 3RD GEAR Hydraulic pressure is applied to the 3rd clutch then the 3rd clutch engages the mainshaft 3rd gear with the mainshaft...

Page 640: ...rse selector with the countershaft 4th gear while the shift lever is in the forward range D4 D3 2 and 1 position Hydraulic pressure is also applied to the 4th clutch then the 4th clutch engages the ma...

Page 641: ...to engage the reverse selector with the countershaft reverse gear while the shift lever is in the R position Hydraulic pressure is also applied to the 4th clutch then the 4th clutch engages the mainsh...

Page 642: ...Transaxle Clutch Pressure Control Solenoid Valve A Automatic Transaxle Clutch Pressure Control Solenoid Valve B 2nd Clutch Pressure Switch 3rd Clutch Pressure Switch Torque Converter Clutch Solenoid...

Page 643: ...SOLENOID PARK PIN SWITCH POWERTRAIN CONTROL MODULE PCM COUNTERSHAFT SPEED SENSOR 2ND CLUTCH PRESSURE SWITCH TRANSMISSION RANGE SWITCH MAINSHAFT SPEED SENSOR 3RD CLUTCH PRESSURE SWITCH SHIFT SOLENOID...

Page 644: ...fting gears between 2nd and 3rd ON OFF OFF Stays in 3rd ON OFF ON D4 Shifting gears between 3rd and 4th OFF OFF ON Stays in 4th OFF OFF OFF 2 2nd ON ON OFF 1 1st OFF ON ON R Shifting from the P and N...

Page 645: ...culation of gradient Selection of shifting mode Normal mode Flat road mode Ascending mode Gradual ascending mode Medium ascending mode Steep ascending mode Descending mode Gradual descending mode Stee...

Page 646: ...o the magnitude of a gradient When the PCM determines that the vehicle is going down a hill in the D4 and D3 positions the shift up speed from 3rd to 4th gear and from 2nd to 3rd when the throttle is...

Page 647: ...SURE SWITCH 3RD CLUTCH 2ND CLUTCH PRESSURE SWITCH OP2SW D13 LC D1 SOLENOID VALVE LOCK UP CONTROL SHIFT CONTROL SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B VALVE A CONTROL SOLENOID A...

Page 648: ...A CONTROL SOLENOID A T CLUTCH PRESSURE LS BM C8 LS AM C1 ATP NP C22 ATP D3 C13 D P R N 1 2 TRANSMISSION RANGE SWITCH A T GEAR POSITION INDICATOR N P D D 2 1 R C21 ATP R C4 ATP D4 C12 ATP 2 C20 ATP 1...

Page 649: ...VSS OUT Vehicle speed signal detected from countershaft speed sensor and sent to speedometer and odometer Depending on vehicle speed Pulsing signal A10 BRN SCS Timing and adjustment service check sig...

Page 650: ...ectrode With ignition switch ON II Pulsing signal B18 GRN LS BM A T clutch pressure control solenoid valve B power supply negative electrode B20 BRN BLK LG1 Ground Less than 1 0 V at all times B21 WHT...

Page 651: ...gear P R and N D8 PNK ATP D3 A T gear position switch D3 position input In the D3 position 0 V In other than the D3 position Battery voltage D9 YEL ATP D4 A T gear position switch D4 position input I...

Page 652: ...on switch ON II Battery voltage With ignition switch OFF 0 V A3 YEL BLK IGP1 Power supply circuit from main relay With ignition switch ON II Battery voltage With ignition switch OFF 0 V A4 BLK PG2 Gro...

Page 653: ...in 2nd and 3rd gears 0 V in these positions 1 D4 and D3 in 1st gear D4 in 4th gear P R and N C3 Not used C4 PNK ATP D3 Transmission range switch D3 position input In the D3 position 0 V In other than...

Page 654: ...ound C15 BLU NC Countershaft speed sensor input Depending on vehicle speed Pulsing signal When vehicle stopped About 0 V C16 Not used C17 GRN SH C Shift solenoid valve C control Battery voltage in the...

Page 655: ...W Brake pedal position switch signal output Brake pedal pressed Battery voltage Brake pedal released 0 V E15 WHT RED ILU Interlock control With ignition switch ON II brake pedal pressed and accelerato...

Page 656: ...y and the accumulator body The ATF pump is driven by splines on the left end of the torque converter which is attached to the engine Fluid flows through the regulator valve to maintain specified press...

Page 657: ...e main valve body contains the manual valve the modulator valve the shift valve C the shift valve D the shift valve E the servo control valve the cooler check valve the torque converter check valve th...

Page 658: ...left side According to the level of the hydraulic pressure through B the position of the regulator valve changes and the amount of fluid from B through torque converter changes This operation is cont...

Page 659: ...ON SERVO BODY ACCUMULATOR BODY 1ST ACCUMULATOR PISTON 2ND ACCUMULATOR PISTON LUBRICATION CHECK VALVE The servo body is on the main valve body It contains the servo valve the shift valve A the shift va...

Page 660: ...utch is engaged by pressure from the CPC pressure mode The PCM controls one of the shift solenoid valves to move the position of the shift valve This movement switches the port of the CPC and line pre...

Page 661: ...MX 4 4 X 3 3 3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 3 10 9 4 X 4 4 1 6 X X 4A 56 4 AX 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H 6 HX AX 56 HX AX 57 6 X X X 6 HX HX M2X 4 M1X AX X 4 57...

Page 662: ...HX AX 57 6 X X X 6 HX HX M2X 4 M1X AX X 4 57 57 58 56 5A 4A 58 5C 48 50 SC 4B 5K 4 4 X 5F 4 30 10 5F 50 5C 5E 5F X 5G 5K SB 9 H3X H3X COUNTER SHAFT MAINSHAFT H7X H6X X X 93 92 SECONDARY SHAFT The PCM...

Page 663: ...IFT VALVE C CPC VALVE B SHIFT VALVE B SHIFT VALVE E 94 90 91 10 20 10 20 30 30 40 40 X X X 90 90 91 58 91 LA 94 91 91 6 96 92 93 X 90 90 58 97 X X 92 2 95 99 X 95 95 AX MX 4 4 X 3 3 3 3 4 3 AX 56 SC 9...

Page 664: ...AX 57 6 X X X HX HX M2X 4 M1X AX X 4 57 57 58 56 5A 4A 58 5C 48 50 SC 4B 5K 4 4 X 5F 4 30 10 5F 50 5C 5E 5F X 5G 5K SB 9 H3X H3X H7X SHIFT VALVE A SHIFT VALVE D MANUAL VALVE SERVO CONTROL VALVE MODUL...

Page 665: ...58 91 LA 94 91 91 6 96 92 93 X 90 90 58 97 X X 92 2 95 99 X 95 95 AX MX 4 4 X 3 3 3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTE...

Page 666: ...3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAFT MAINSHAFT H6X X X 93 92 X 90 93 93 X 6 6 6 HX 56 HX AX 57 6 X X X HX HX M2...

Page 667: ...LA 94 91 91 6 96 92 93 X 90 90 58 97 X X 92 2 95 99 X 95 95 AX MX 4 4 X 3 3 3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAF...

Page 668: ...3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAFT MAINSHAFT H6X X X 93 92 X 90 93 93 X 6 6 6 HX 56 HX AX 57 6 X X X HX HX M2X...

Page 669: ...56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAFT MAINSHAFT H6X X X 93 92 X 90 93 93 X 6 6 6 HX 56 HX AX 57 6 X X X HX HX M2X 4 M1X AX X...

Page 670: ...J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAFT MAINSHAFT H6X X X 93 92 X 90 93 93 X 6 6 6 HX 56 HX AX 57 6 X X X HX HX M2X 4 M1X AX X 4 57 57 58 56 5A 4A 58 5C 48 50 SC 4B 5K 4 4 X 5F...

Page 671: ...X X 92 2 95 99 X 95 95 AX MX 4 4 X 3 3 3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57 5E 5F 5K 5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAFT MAINSHAFT H6X X X 93 92 X 90 93 93 X...

Page 672: ...94 90 91 10 20 10 20 30 30 40 40 X X X 90 90 91 58 91 LA 94 91 91 6 96 92 93 X 90 90 58 97 X X 92 2 95 99 X 95 95 AX MX 4 4 X 3 3 3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 25 41 5J 5H 57...

Page 673: ...5K 5G 20 X 5A 5A 58 X X 5J 5A 5H COUNTER SHAFT MAINSHAFT H6X X X 93 92 X 90 93 93 X 6 6 6 HX 56 HX AX 57 6 X X X HX HX M2X 4 M1X AX X 4 57 57 58 56 5A 4A 58 5C 48 50 SC 4B 5K 4 4 X 5F 4 30 10 5F 50 5C...

Page 674: ...SHIFT VALVE E 94 90 91 10 20 10 20 30 30 40 40 X X X 90 90 91 58 91 LA 94 91 91 6 96 92 93 X 90 90 58 97 X X 92 2 95 99 X 95 95 AX MX 4 4 X 3 3 3 3 4 3 AX 56 SC 95 4 1 25 3 41 40 3 10 9 4 4 4 1 X 9 2...

Page 675: ...que converter clutch solenoid valve activates modulator pressure changes to switch lock up ON and OFF The lock up control valve and the lock up timing valve control the amount of lock up according to...

Page 676: ...URE RELIEF VALVE The torque converter clutch solenoid valve is turned OFF by the PCM The lock up shift valve receives LC pressure LA on the left side and modulator pressure 6 on the right side The loc...

Page 677: ...re to the left side and right side of the torque converter Torque converter pressure 92 flows to the right side of the torque converter to engage the torque converter clutch The PCM also controls A T...

Page 678: ...VE TORQUE CONVERTER CLUTCH SOLENOID VALVE LS A or LS B PRESSURE MODULATOR PRESSURE When the vehicle speed further increases the PCM controls A T clutch pressure control solenoid valves A and B to incr...

Page 679: ...S MULTIPLEX CONTROL 7 5A No 13 LT BLU E ST A PG2 B10 PG1 B2 B9 IGP2 IGP1 B1 B21 VBU G101 BLK BLK YEL BLK PGM FI MAIN RELAY To 5V CPU No 9 10A IG1 BAT No 54 40A No 46 15A CONTROL BLK G503 UNDER DASH F...

Page 680: ...SSURE CONTROL SOLENOID VALVE B SOLENOID VALVE A PRESSURE CONTROL A T CLUTCH GRN ORN RED WHT SWITCH PRESSURE 2ND CLUTCH D13 OP2SW BLU BLK 3RD CLUTCH PRESSURE SWITCH SPEED SENSOR MAINSHAFT WHT D12 NMSG...

Page 681: ...MULTIPLEX CONTROL 7 5A No 13 LT BLU E ST A PG2 A4 PG1 A5 A2 IGP2 IGP1 A3 A1 VBU G101 BLK BLK YEL BLK PGM FI MAIN RELAY To 5V CPU No 9 10A IG1 BAT No 54 40A No 46 15A CONTROL BLK G503 UNDER DASH FUSE...

Page 682: ...G401 BLK WHT RED WHT YEL WHT YEL ASSSEMBLY STEERING LOCK SOLENOID INTERLOCK KEY SWITCH INTERLOCK KEY WHT RED OP3SW C19 BK SW DATA LINK CONNECTOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE POSITION SEN...

Page 683: ...k 2 Disconnect the 2P connector from the mainshaft speed sensor 3 Measure mainshaft speed sensor resistance at the sensor connector Go to step 4 Replace the mainshaft speed sensor see page 14 134 4 Di...

Page 684: ...sensor connector Go to step 10 Repair open in the wire between the D11 terminal and the mainshaft speed sensor 10 Check for continuity between the D12 terminal and the No 2 terminal of the mainshaft s...

Page 685: ...e countershaft speed sensor see page 14 134 4 Disconnect the D 16P connector from the PCM 5 Check for continuity between body ground and the D10 terminal and D16 terminal individually Repair short to...

Page 686: ...ooting until the causes of any other DTCs have been corrected 2 Measure the 1st 2nd 3rd and 4th clutch pressure see page 14 128 Go to step 3 Repair the hydraulic system as necessary 3 Replace the Sole...

Page 687: ...ure see page 14 128 Go to step 3 Replace the transmission 3 Replace the Lock up Control Solenoid Assembly set lock up control solenoid valve shift control solenoid valve A assembly see page 14 130 and...

Page 688: ...itch OFF 2 Disconnect the B 25P and D 16P connectors from the PCM 3 Turn the ignition switch ON II 4 Measure the voltage between the D7 and B20 or B22 terminals Repair short to power in the wire betwe...

Page 689: ...minal of the lock up control solenoid valve shift control solenoid valve A assembly connector and body ground Check for an open in the wire between the D7 terminal and shift control solenoid valve A R...

Page 690: ...h OFF 2 Disconnect the B 25P and D 16P connectors from the PCM 3 Turn the ignition switch ON II 4 Measure the voltage between the D2 and B20 or B22 terminals Repair short to power in the wire between...

Page 691: ...for an open in the wires between the D2 terminal and the shift control solenoid valve B and between the No 1 terminal of the shift control solenoid valve B connector and ground G101 Replace the shift...

Page 692: ...CM 3 Turn the ignition switch ON II 4 Measure the voltage between the D3 and B20 or B22 terminals Repair short to power in the wire between the D3 terminal and the shift control solenoid valve C Go to...

Page 693: ...ck for an open in the wires between the D3 terminal and the shift control solenoid valve C and between the No 1 terminal of the shift control solenoid valve C connector and ground G101 Replace shift c...

Page 694: ...n R 7 Measure the voltage between the D6 and B20 or B22 terminals Go to step 8 Check for a short in the wire between the D6 terminal and the A T gear position switch or A T gear position indicator and...

Page 695: ...icator If wire is OK check for loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck 12 Shift to all positions other than D3 13 Measure the voltage between the...

Page 696: ...the PCM connectors If necessary substitute a known good PCM and recheck 16 Shift to all positions other than 1 17 Measure the voltage between the D15 and B20 or B22 terminals Check for loose terminal...

Page 697: ...lace the A T gear position switch see page 14 174 2 Turn the ignition switch OFF 3 Check for continuity between the B20 and B22 terminals and body ground Go to step 4 Repair open in the wires between...

Page 698: ...minals Repair open in the wire between the D8 terminal and the A T gear position switch Go to step 13 13 Shift to 2 position 14 Measure the voltage between the D14 and B20 or B22 terminals Repair open...

Page 699: ...tion switch ON II 2 Measure the voltage between the D13 and B20 or B22 terminals Go to step 7 Go to step 3 3 Turn the ignition switch OFF 4 Disconnect the D 16P connector from the PCM 5 Disconnect the...

Page 700: ...CM and recheck Go to step 11 11 Turn the ignition switch OFF 12 Disconnect the 2nd clutch pressure switch connector 13 Turn the ignition switch ON II 14 Measure the voltage between the 2nd clutch pres...

Page 701: ...switch ON II 2 Measure the voltage between the B24 and B20 or B22 terminals Go to step 7 Go to step 3 3 Turn the ignition switch OFF 4 Disconnect the B 25P connector from the PCM 5 Disconnect the 3rd...

Page 702: ...d PCM and recheck Go to step 11 11 Turn the ignition switch OFF 12 Disconnect the 3rd clutch pressure switch connector 13 Turn the ignition switch ON II 14 Measure the voltage between the 3rd clutch p...

Page 703: ...16P connectors from the PCM 3 Turn the ignition switch ON II 4 Measure the voltage between the D1 and B20 or B22 terminals Repair short to power in the wire between the D1 terminal and the lock up co...

Page 704: ...noid valve shift control solenoid valve A assembly connector and body ground Check for an open in the wire between the D1 terminal and the lock up control solenoid valve Replace the lock up control so...

Page 705: ...solenoid resistance at the solenoid valve connector Go to step 3 Replace the A T clutch pressure control solenoid valve A B assembly see page 14 133 3 Disconnect the B 25P connector from the PCM 4 Ch...

Page 706: ...se relay box If the fuse is OK repair open in the wire between the D5 terminal and the driver s under dash fuse relay box 10 Turn the ignition switch OFF 11 Check for continuity between the B20 and B2...

Page 707: ...olenoid resistance at the solenoid valve connector Go to step 3 Replace the A T clutch pressure control solenoid valve A B assembly see page 14 133 3 Disconnect the B 25P connector from the PCM 4 Chec...

Page 708: ...ay box If the fuse is OK repair open in the wire between the D5 terminal and the driver s under dash fuse relay box 10 Turn the ignition switch OFF 11 Check for continuity between the B20 and B22 term...

Page 709: ...heck 2 Disconnect the mainshaft speed sensor connector 2P 3 Measure the mainshaft speed sensor resistance at the sensor connector Go to step 4 Replace the mainshaft speed sensor see page 14 134 4 Disc...

Page 710: ...tor Go to step 10 Repair open in the wire between PCM connector terminal C7 and the mainshaft speed sensor 10 Check for continuity between PCM connector terminal C6 and the No 2 terminal of the mainsh...

Page 711: ...or connector Go to step 4 Replace the countershaft speed sensor see page 14 134 4 Disconnect PCM connector C 22P 5 Check for continuity between PCM connector terminal C14 and body ground and between t...

Page 712: ...ed 2 Measure the 1st 2nd 3rd and 4th clutch pressure see page 14 128 Go to step 3 Replace the transmission 3 Replace the shift solenoid torque converter clutch solenoid and A T clutch pressure control...

Page 713: ...the torque converter clutch solenoid and A T clutch pressure control solenoid valve set Refer to Torque Converter Clutch Solenoid Valve Shift Solenoid Valve A Replacement see page 14 130 Refer to A T...

Page 714: ...and C 22P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals C2 and A25 or A26 Repair short to power in the wire between PCM connector terminal C2 and the shift so...

Page 715: ...converter clutch solenoid valve shift solenoid valve A connector and body ground Check for an open in the wire between the C2 terminal and the shift solenoid valve A Replace the torque converter clut...

Page 716: ...and C 22P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals C9 and A25 or A26 Repair short to power in the wire between PCM connector terminal C9 and the shift so...

Page 717: ...een PCM connector terminal C9 and the shift solenoid valve B and between the No 1 terminal of the shift solenoid valve B connector and body ground G101 Replace the shift solenoid valve B see page 14 1...

Page 718: ...31P and C 22P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals C17 and A25 or A26 Repair short to power in the wire between PCM connector terminal C17 and the shi...

Page 719: ...en PCM connector terminal C17 and the shift solenoid valve C and between the No 1 terminal of the shift solenoid valve C connector and body ground G101 Replace shift control solenoid valve C see page...

Page 720: ...Perform the Troubleshooting Flowchart for the indicated Code s Recheck for code P0780 after troubleshooting Go to step 2 NOTE Do not continue with this troubleshooting until the causes of any other DT...

Page 721: ...y position other than R 7 Measure the voltage between PCM connector terminals C21 and A25 or A26 Go to step 8 Check for a short in the wire between PCM connector terminal C21 and the transmission rang...

Page 722: ...the wire is OK check for loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck 12 Shift to any position other than D3 13 Measure the voltage between PCM connect...

Page 723: ...or loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck 16 Shift to any position other than 1 17 Measure the voltage between PCM connector terminals C20 and A2...

Page 724: ...F 3 Check for continuity between PCM connector terminal A25 and body ground and between terminal A26 and body ground Go to step 4 Repair open in the wires between PCM connector terminals A25 and A26 a...

Page 725: ...minals C4 and A25 or A26 Repair open in the wire between PCM connector terminal C4 and the transmission range switch Go to step 13 13 Shift to 2 position 14 Measure the voltage between PCM connector t...

Page 726: ...between PCM connector terminals C11 and A25 or A26 Go to step 7 Go to step 3 3 Turn the ignition switch OFF 4 Disconnect PCM connector C 22P 5 Disconnect the 2nd clutch pressure switch connector 6 Che...

Page 727: ...y substitute a known good PCM and recheck Go to step 11 11 Turn the ignition switch OFF 12 Disconnect the 2nd clutch pressure switch connector 13 Turn the ignition switch ON II 14 Measure the voltage...

Page 728: ...between PCM connector terminals C19 and A25 or A26 Go to step 7 Go to step 3 3 Turn the ignition switch OFF 4 Disconnect PCM connector C 22P 5 Disconnect the 3rd clutch pressure switch connector 6 Che...

Page 729: ...If necessary substitute a known good PCM and recheck Go to step 11 11 Turn the ignition switch OFF 12 Disconnect the 3rd clutch pressure switch connector 13 Turn the ignition switch ON II 14 Measure t...

Page 730: ...er code Perform the Troubleshooting Flowchart for the indicated Code s Recheck for code P1750 after troubleshooting Go to step 2 2 Turn the ignition switch OFF 3 Replace the A T clutch pressure contro...

Page 731: ...olenoid valves A and B 1 Check whether the scan tool or the HDS indicates another code Perform the Troubleshooting Flowchart for the indicated Code s Recheck for code P1751 after troubleshooting Go to...

Page 732: ...d C 22P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals C10 and A25 or A26 Repair short to power in the wire between PCM connector terminal C10 and the torque co...

Page 733: ...onverter clutch solenoid valve shift solenoid valve A connector and body ground Check for an open in the wire between the C10 terminal and the torque converter clutch solenoid valve Replace the torque...

Page 734: ...ve A connector Go to step 3 Replace the A T clutch pressure control solenoid valve A and B see page 14 133 3 Disconnect PCM connectors B 24P and C 22P 4 Check for continuity between PCM connector term...

Page 735: ...ay box If the fuse is OK repair open in the wire between PCM connector terminal B24 and the driver s under dash fuse relay box 10 Turn the ignition switch OFF 11 Check for continuity between PCM conne...

Page 736: ...alve connector Go to step 3 Replace the A T clutch pressure control solenoid valves A and B see page 14 133 3 Disconnect PCM connectors B 24P and C 22P 4 Check for continuity between PCM connector ter...

Page 737: ...known good PCM and recheck Go to step 10 10 Turn the ignition switch OFF 11 Check for continuity between PCM connector terminal A25 and body ground and between terminal A26 and body ground Check for...

Page 738: ...tall 3 Repeat step 2 in the D3 position 4 Connect the HDS to the DLC A and go to the PGM FI Data List then go to step 7 If you don t have a HDS go to step 5 5 Pull back the carpet and remove the passe...

Page 739: ...ON 116 120 mph 184 192 km h Lock up OFF 45 49 mph 72 78 km h 4th 3rd 19 21 mph 30 34 km h 3rd 1st 7 9 mph 10 14 km h Lock up OFF 70 74 mph 112 118 km h 4th 3rd 48 52 mph 77 83 km h 3rd 2nd 27 29 mph 4...

Page 740: ...positions NOTE Do not test stall speed for more than 10 seconds at a time Stall speed tests should be used for diagnostic purposes only Stall speed should be the same in D4 2 1 and R positions Do not...

Page 741: ...n fluid is filled to the proper level 2 Raise the vehicle and make sure it is securely supported 3 Allow all four wheels to rotate freely 4 Warm up the engine the radiator fan comes on then stop it an...

Page 742: ...16 Press the accelerator very slowly to increase engine speed to 2 000 rpm gradually over 5 seconds then hold it at 2 000 rpm 17 Measure 3rd and 4th clutch pressure at 3rd clutch pressure inspection h...

Page 743: ...andard connect the No 1 terminal of the 3P connector to the battery positive terminal A clicking sound should be heard Connect the No 3 terminal to the battery positive terminal A clicking sound shoul...

Page 744: ...al A clicking sound should be heard Replace the shift solenoid valve B or C if no clicking sound is heard NOTE If the shift solenoid valve B and C are replaced or removed at the same time be sure to r...

Page 745: ...sound should be heard 5 If not remove the A T clutch pressure control solenoid valves A and B 6 Check the fluid passage of the A T clutch pressure control solenoid valves for dust and dirt and clean t...

Page 746: ...d valves A and B A 5 Clean the mounting surface and fluid passages of the A T clutch pressure control solenoid valves A and B and the transmission housing 6 Place a new gasket B on the transmission ho...

Page 747: ...lt securing the mainshaft speed sensor then remove the mainshaft speed sensor from the end cover 3 Remove the bolt securing the countershaft speed sensor then remove the countershaft speed sensor A an...

Page 748: ...aling washer Tighten the switch on the metal part not the plastic part 3 Reconnect the connector making sure there is no water oil dust or other foreign particles inside it 1 Disconnect the connector...

Page 749: ...ansmission 5 Remove the dipstick and check the fluid level It should be between the upper mark B and lower mark C 6 If the level is below the lower mark check for fluid leaks at the transmission hose...

Page 750: ...rk the vehicle on the level ground and turn the engine off 3 Remove the ATF filler bolt and the drain plug A and drain the automatic transmission fluid ATF NOTE If a cooler flusher is used refer to AT...

Page 751: ...move the positive terminal 5 Remove the battery hold down bracket then remove the battery and battery tray 6 Remove the battery cable clamps connector and relay bracket from the battery base 7 Remove...

Page 752: ...id valve A A then remove the connector from harness cover B 16 Remove the bolt securing connector bracket C 17 Remove the bolt securing the harness cover then push the harness cover rearward to remove...

Page 753: ...sing mounting bolts 22 Remove the engine covers 23 Lift and support the engine with engine support hanger A and engine balance bar B Attatch the front arm C to the front cylinder head with a spacer D...

Page 754: ...29 Remove the bolts securing the shift cable holder A then remove the shift cable cover B NOTE To prevent damage to the control lever C remove the bolts securing the holder before removing the bolts s...

Page 755: ...ove the engine stiffener bolts C 34 Remove the clip A on the power steering fluid return hose B from the bracket C 35 Remove the power steering fluid pipe bracket bolts D and bracket E and remove the...

Page 756: ...oss the marks B on the edge of the front subframe C 42 Loosen the four bolts A holding the adjustable arms B of the front subframe adapter T N EQ07AODSY0 to its center plate NOTE The adapter is design...

Page 757: ...o vehicle height then attach the adapter to the front subframe by sliding the adapter s nut plates B between the subframe and the body 45 Insert the nut plate bolts through the holes in the adapter an...

Page 758: ...front side Coat all precision finished surfaces with clean engine oil then tie the plastic bags over the driveshaft ends 51 Remove the intermediate shaft 52 Coat all precision finished surfaces with...

Page 759: ...then lower it on the transmission jack NOTE If the torque converter is stuck to the drive plate pull it toward the transmission housing from the starter opening 58 Remove the shift cable cover then re...

Page 760: ...ler see page 14 155 2 Install the transmission lower mounts A 3 Install the torque converter assembly A on the mainshaft B with a new O ring C 4 Install the 14 mm dowel pin D and 10 mm dowel pin E in...

Page 761: ...he specified torque then to the final torque in a crisscross pattern After tightening the last bolt check that the crankshaft rotates freely 10 Install the torque converter cover D 11 Tighten the cran...

Page 762: ...ntacts the transmission differential with solvent or carburetor cleaner and dry with compressed air Turn the right and left steering knuckle fully outward and slide the left driveshaft into the differ...

Page 763: ...ft 10 x 1 25 mm 59 N m 6 0 kgf m 43 lbf ft B 10 x 1 25 mm 58 N m 5 9 kgf m 43 lbf ft C A 10 x 1 25 mm 59 N m 6 0 kgf m 43 lbf ft 18 Install the transmission lower mount nuts 19 Install the power steer...

Page 764: ...Do not bend the shift cable excessively 26 Install the lock bolt D with a new lock washer E then bend the lock washer tab against the bolt 27 Install the shift cable cover F then install the shift cab...

Page 765: ...ion housing mounting bolts 34 Install and tighten the nut A on the front mount 35 Connect the vacuum tube B 36 Remove the engine hanger 37 Connect the A T gear position switch connector A then install...

Page 766: ...r 41 Connect the connectors to the 3rd clutch pressure switch A mainshaft speed sensor B and A T clutch pressure control solenoid valves A and B C then install the clamps on the clamp brackets Do not...

Page 767: ...nnect the negative terminal 53 Set the parking brake Start the engine and shift the transmission through all gears three times 54 Check the shift lever operation A T gear position indicator operation...

Page 768: ...opposite end of the drain hose to a bucket D or floor drain 7 With the water and air valves A off attach the water and air supplies to the flusher Hot water if available 8 Turn on the water valve for...

Page 769: ...ith ATF and run the engine for 30 seconds or until approximately 0 95 1 0 US qt is discharged 18 Remove the drain hose and reconnect the cooler return hose to the transmission 19 Refill the transmissi...

Page 770: ...position 3 Remove the nut A securing the shift cable end B then separate the shift cable C from the shift lever assembly D 4 Rotate the socket holder E on the shift cable counterclockwise a quarter t...

Page 771: ...s see page 23 18 and the precautions and procedures see page 23 21 in the SRS before performing repairs or service 1 Install the shift lever assembly on the steering column 2 Turn the ignition switch...

Page 772: ...TENT SPRING SHIFT LOCK EXTENSION SHIFT LOCK CUSHION SHIFT LOCK SOLENOID PLUNGER PLUNGER SPRING 4 mm SCREW 3 N m 0 3 kgf m 2 lbf ft WASHER SHIFT LEVER KNOB 9 N m 0 9 kgf m 7 lbf ft Apply silicone greas...

Page 773: ...mission into the N position 5 Remove the nut A securing the shift cable end B then separate the shift cable C from the shift lever assembly D 6 Rotate the socket holder E on the shift cable counterclo...

Page 774: ...bend the shift cable excessively 13 Install the lock bolt D with a new lock washer E then bend the lock washer tab against the bolt head 14 Install the shift cable cover F then install the shift cable...

Page 775: ...the shift lever assembly D 4 Rotate the socket holder E on the shift cable counterclockwise a quarter turn then slide the holder to remove the shift cable from the shift cable bracket F NOTE Do not re...

Page 776: ...shift cable guide H 10 Verify that the shift cable end A is properly installed on the mounting stud B 11 If improperly installed remove the shift cable from the shift cable bracket and reinstalled th...

Page 777: ...ITION INDICATOR POWERTRAIN CONTROL MODULE PCM TRANSMISSION RANGE SWITCH D4 Indicator Cicuit Troubleshooting 1999 2000 models page 14 166 2001 model page 14 169 Indicator Input Test page 14 172 Test pa...

Page 778: ...IND R 1 2 UNIT CRUISE BLK G101 RED WHT PNK GRY BLK BLU WHT RED YEL GRN BLU BRN BRN BLU PNK RED BLK WHT BLK BLU GRN BLK BRN BLU PNK YEL WHT POWERTRAIN CONTROL MODULE PCM DRIVER S UNDER DASH IGNITION SW...

Page 779: ...7 Turn the ignition switch OFF 8 Reconnect the A 32P and D 16P connectors to the PCM 9 Turn the ignition switch ON II 10 Shift to any position other than D4 11 Measure the voltage between the D9 term...

Page 780: ...nd B22 and between terminals B9 and B20 Go to step 19 Repair open or short in the wire between the B1 or B9 terminal and the PGM FI main relay 19 Turn the ignition switch OFF 20 Reconnect the B 25P co...

Page 781: ...nnect PCM connector A 32P 25 Check for continuity between the A14 terminal and body ground Repair short to ground in the wire between the A14 terminal and the gauge assembly Check for loose terminal f...

Page 782: ...PCM connectors C 22P and E 31P 9 Turn the ignition switch ON II 10 Shift to any position other than D4 11 Measure the voltage between PCM connector terminal C13 and body ground Faulty PCM or gauge as...

Page 783: ...II 18 Measure the voltage between PCM connector terminals A2 and A25 and between terminals A3 and A26 Go to step 19 Repair open or short in the wire between PCM connector terminals A2 or A3 and the P...

Page 784: ...ity between PCM connector terminal E5 and body ground Repair short to ground in the wire between PCM connector terminal E5 and the gauge assembly Check for loose terminal fit in the PCM connectors Che...

Page 785: ...nd G501 An open in the wire B22 RED BLK Headlights ON Check for voltage to ground There should be battery voltage Blown No 10 15A fuse in the passenger s under dash fuse relay box An open in the wire...

Page 786: ...1 Transmission Range Switch Continuity Check N 1 Remove the transmission range switch connector A from the connector bracket B then disconnect the connector 2 Check for continuity between the termina...

Page 787: ...range switch connector A from the connector bracket B then disconnect the connector 5 Remove the clamp from the harness clamp bracket on the transmission housing then remove the harness clamp A from...

Page 788: ...ver C and the harness clamp D on the end cover E 11 Connect the transmission range switch connector A then install it on the connector bracket B 12 Turn the ignition switch ON II Move the shift lever...

Page 789: ...ated in this area Review the SRS component locations see page 23 18 and the precautions and procedures see page 23 21 in the SRS before performing repairs or service 1 Remove the gauge assembly see pa...

Page 790: ...INTERLOCK SWITCH STEERING LOCK ASSEMBLY KEY INTERLOCK SOLENOID Shift Lock System Circuit Troubleshooting page 14 179 Input Test page 14 184 Shift Lock System Circuit Troubleshooting page 14 179 Test p...

Page 791: ...G BLK B11 A15 A2 A12 YEL BLK PG POWERTRAIN CONTROL MODULE PCM ILU E15 2001 WHT RED BLK BLU ATP P ILU B12 B22 GRN 2 1 YEL IG1 BAT IGNITION SWITCH No 9 10A UNDER HOOD FUSE RELAY BOX No 42 50A No 41 120A...

Page 792: ...2001 model and the multiplex control unit driver s and check for loose terminal fit in the multiplex control unit driver s connectors If necessary substitute a known good multiplex control unit driver...

Page 793: ...nector 13 Turn the ignition switch ON II 14 Measure the voltage between the No 1 and No 3 terminals of the TPS connector Check for an open or short in the wire between the C27 terminal and the TPS If...

Page 794: ...the driver s under dash fuse relay box If the fuse is OK repair open or short in the wire between the No 1 terminal of the shift lock solenoid and the driver s under dash fuse relay box 20 Connect the...

Page 795: ...itch Replace the ignition key cylinder steering lock assembly 5 Measure the voltage between the No 7 terminal and body ground Go to step 6 Check for a blown No 47 20A fuse in the under hood fuse relay...

Page 796: ...in switch connector and the No 5 terminal of the key switch connector 9 Check for continuity between the No 1 terminal of the park pin switch connector and body ground Check for a loose key switch con...

Page 797: ...s a problem find and correct the cause then recheck the system If all the input tests prove OK go to step 4 A2 Under all conditions Check for continuity to ground There should be continuity Poor groun...

Page 798: ...solenoid is not available separately SRS components are located in this area Review the SRS component locations see page 23 18 and the precautions and procedures see page 23 21 in the SRS before perf...

Page 799: ...hen separate the shift cable C from the shift lever assembly D 4 Disconnect the shift lock solenoid connector A and the park pin switch connector B 5 Remove the three bolts C securing the shift lever...

Page 800: ...ers see page 17 25 2 Disconnect the park pin switch connector 3 Shift the shift lever into the P position then check for continuity between the No 1 and No 3 terminals There should be no continuity 4...

Page 801: ...FT IDLER GEAR BREATHER TUBE ATF COOLER LINE LINE BOLT ATF COOLER LINE SEALING WASHERS PARK PAWL SHAFT PARK GEAR NEEDLE BEARING THRUST NEEDLE BEARING COUNTERSHAFT IDLER GEAR THRUST NEEDLE BEARING CONIC...

Page 802: ...ion pitot pipe B from the transmission housing C then remove the pitot flange D from the mainshaft idler gear E 5 Slip the special tool onto the mainshaft 6 Engage the park pawl with the park gear 7 C...

Page 803: ...1 Remove the park gear F with the puller 12 Remove the park pawl spring shaft and shaft stop 13 Remove the park lever from the control shaft 14 Remove the line bolts then remove the ATF cooler lines 1...

Page 804: ...RANSMISSION HANGER REVERSE IDLER GEAR MAINSHAFT SUBASSEMBLY TORQUE CONVERTER HOUSING DIFFERENTIAL ASSEMBLY COUNTERSHAFT SUBASSEMBLY SECONDARY SHAFT SUBASSEMBLY COUNTERSHAFT 4TH GEAR REVERSE SELECTOR H...

Page 805: ...roove C by turning the control shaft 5 Install the special tool over the mainshaft then remove the transmission housing D NOTE If the top arm of your housing puller is too short replace it with Housin...

Page 806: ...ransmission housing expand each snap ring with the snap ring pliers then push the bearing out NOTE Do not remove the snap rings unless it s necessary to clean the grooves in the housing 2 Install the...

Page 807: ...VE GEAR ATF PUMP DRIVEN GEAR MAIN SEPARATOR PLATE TORQUE CONVERTER CHECK VALVE DOWEL PINS Three Pins TORQUE CONVERTER CHECK VALVE SPRING TORQUE CONVERTER HOUSING ACCUMULATOR BODY 6 x 1 0 mm Six Bolts...

Page 808: ...stop 9 Remove the regulator separator plate and dowel pins two 10 Unhook the detent spring from the detent arm then remove the detent arm shaft detent arm and control shaft 11 Remove the cooler check...

Page 809: ...y it with compressed air 4 Roll up half a sheet of ATF soaked 600 paper and insert it in the valve bore of the sticking valve Twist the paper slightly so that it unrolls and fits the bore tightly then...

Page 810: ...r valve body see page 14 201 and servo body see page 14 202 Refer to the following valve cap illustrations and install each valve cap so the end shown facing up will be facing the outside of the valve...

Page 811: ...LVE 1 Clean all parts thoroughly in solvent or carburetor cleaner and dry them with compressed air Blow out all passages 2 Do not use a magnet to remove the check valve ball it may magnetize the ball...

Page 812: ...spring 0 7 0 028 6 6 0 260 35 7 1 406 17 2 Shift valve E spring 0 7 0 028 6 1 0 240 17 8 0 701 7 9 Relief valve spring 1 1 0 043 8 6 0 339 30 1 1 185 10 7 Lock up shift valve spring 0 9 0 035 7 6 0 29...

Page 813: ...Pump Inspection A B C D A B B D A C 1 Install the ATF pump drive gear A driven gear B and ATF pump driven gear shaft C in the main valve body D Lubricate all parts with ATF and install the ATF pump dr...

Page 814: ...aged 4 Hold the regulator spring cap in place while removing the stop bolt The regulator spring cap is spring loaded Once the stop bolt is removed release the spring cap slowly so it does not pop out...

Page 815: ...If any fail to slide freely refer to Valve Body Repair see page 14 196 3 Replace the valve body as an assembly if any parts are worn or damaged 4 Coat all parts with ATF during reassembly Shift valve...

Page 816: ...R BODY COVER 1 Do not use a magnet to remove the check balls it may magnetize the balls 2 Clean all parts thoroughly in solvent or carburetor cleaner and dry them with compressed air Blow out all pass...

Page 817: ...25 40 mm 07736 A01000B or 07736 A01000A Driver 07749 0010000 Attachment 62 x 68 mm 07746 0010500 Attachment 72 x 75 mm 07746 0010600 1 Remove the mainshaft bearing and oil seal with the special tool a...

Page 818: ...0010000 Attachment 62 x 68 mm 07746 0010500 1 Remove the countershaft bearing A with the special tool and a commercially available 3 8 16 slide hammer B 2 Install the ATF guide plate A 3 Install the...

Page 819: ...0 kgf m 7 2 lbf ft PITOT FLANGE 1 Lubricate all parts with ATF during reassembly 2 Check the clearance of the 3rd 4th clutch assembly see page 14 207 3 Inspect the thrust needle bearing and the needle...

Page 820: ...asure the clearance between the clutch guide E and the 4th gear collar with a feeler gauge F in at least three places Use the average as the actual clearance 4 If the clearance is out of standard remo...

Page 821: ...m only if they are worn distorted or damaged 1 For a better fit squeeze sealing rings together slightly before installing them 2 Apply ATF to the new sealing rings then install them on the mainshaft 3...

Page 822: ...off components down to the reverse selector hub 2 Remove the reverse selector hub 3rd gear and 1st gear see page 14 210 3 Check the bearing in the bearing hub for wear and rough movement If the bearin...

Page 823: ...countershaft and press to prevent damaging the countershaft NOTE Some reverse selector hubs are not press fitted and can be removed without using a puller 2 Remove the needle bearing snap ring distan...

Page 824: ...acts the final drive gear D 3 Align the shaft splines with those on 3rd gear then press the countershaft into the 3rd gear with a press Place an attachment between the press and countershaft to preven...

Page 825: ...749 0010000 Attachment 42 x 47 mm 07746 0010300 Attachment 62 x 68 mm 07746 0010500 1 Check the bearing for wear damage and rough movement If the bearing is worn or damaged replace it 2 Remove the bea...

Page 826: ...isassemble the shaft and gears 2 Inspect the thrust needle bearing and the needle bearing for galling and rough movement 3 Check clearance of the secondary shaft assembly see page 14 214 4 Check the s...

Page 827: ...retainer G and snap ring H on the secondary shaft I 3 Measure the clearance between the 38 x 56 5 mm splined washer E and cotters F with a feeler gauge J in at least three places Use the average as t...

Page 828: ...x 5 mm thrust washer G against the clutch assembly A and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear E Use the average as the actual clearance 10 If the cl...

Page 829: ...6 0010500 1 Check the bearing for wear damage and rough movement If the bearing is worn or damaged go to step 2 2 Place the secondary shaft idler gear in a vise with soft jaws 3 Remove the bearing A f...

Page 830: ...ompressor bolt assembly 07GAE PG40200 or 07GAE PG4020A 1 Remove the snap ring A then remove the clutch end plate the clutch discs and the plates with a screwdriver B 2 Remove the disc spring A from th...

Page 831: ...e special tool contacts the clutch return spring C 6 If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring the retainer may be damaged...

Page 832: ...19 A B 9 For 3rd and 4th clutch Wrap a shop rag around the clutch drum A and apply air pressure to the fluid passage to remove the piston B Place a finger tip on the other end while applying air press...

Page 833: ...O RINGS 2ND CLUTCH DRUM 1ST CLUTCH DRUM CLUTCH DISCS CLUTCH DISCS O RINGS CLUTCH PISTON DISC SPRING RETURN SPRING O RING SPRING RETAINER SNAP RING CLUTCH PLATE CLUTCH END PLATE SNAP RING Standard thic...

Page 834: ...UTCH DISCS SNAP RING CLUTCH END PLATE CLUTCH PLATES SNAP RING SPRING RETAINER RETURN SPRING O RINGS 4TH CLUTCH DRUM CHECK VALVE DISC SPRING CLUTCH PISTON DISC SPRING 3RD CLUTCH DRUM Replace Standard t...

Page 835: ...ughly in solvent or carburetor cleaner and dry them with compressed air Blow out all passages Apply ATF to all parts before assembly 1 Soak the clutch discs thoroughly in ATF for a minimum of 30 minut...

Page 836: ...the clutch assembly 7 Be sure the special tool A is adjusted to have full contact with the spring retainer B on the 3rd and 4th clutches 8 Set the special tool A on the spring retainer B of the 1st an...

Page 837: ...he 1st 3rd and 4th clutches in the direction shown NOTE The 2nd clutch does not have a disc spring 14 Make sure the inside of the clutch drum is free of dirt and other foreign matter 15 Starting with...

Page 838: ...etween the clutch end plate and top disc D Take measurements in at least three places and use the average as the actual clearance 21 If the clearance is not within the service limit select a new clutc...

Page 839: ...ATOR PLATE TORQUE CONVERTER CHECK VALVE DOWEL PINS Three Pins TORQUE CONVERTER CHECK VALVE SPRING TORQUE CONVERTER HOUSING ACCUMULATOR BODY 6 x 1 0 mm Six Bolts SERVO SEPARATOR PLATE DOWEL PINS Two Pi...

Page 840: ...eck movement Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft 4 Install the cooler check valve and spring on the main...

Page 841: ...ERSE IDLER GEAR MAINSHAFT SUBASSEMBLY TORQUE CONVERTER HOUSING DIFFERENTIAL ASSEMBLY COUNTERSHAFT SUBASSEMBLY SECONDARY SHAFT SUBASSEMBLY COUNTERSHAFT 4TH GEAR REVERSE SELECTOR HUB REVERSE SELECTOR SH...

Page 842: ...ub installation procedures see page 14 211 3 Turn the shift fork shaft A so the large chamfered hole is facing the fork bolt hole Then install the shift fork B and reverse selector C together on the s...

Page 843: ...e the transmission housing on the torque converter housing then install the transmission housing mounting bolts along with the harness clamp bracket A transmission hanger B and transmission hanger har...

Page 844: ...d locknut Threads of the countershaft and the old locknut Old conical spring washer 3 Install the park gear A using the old locknut B and a collar C Hold the park pawl D against the park gear then tig...

Page 845: ...er gear C thrust needle bearing D bearing hub bearing assembly E and the old conical spring washer F Then tighten the old locknut G to 164 N m 17 0 kgf m 123 lbf ft NOTE Use a torque wrench to tighten...

Page 846: ...ines of the mainshaft secondary shaft and idler gears Threads of the mainshaft and secondary shaft Threads of the old mainshaft and secondary shaft locknuts Old conical spring washers 15 Install the m...

Page 847: ...he locknut Do not use an impact wrench Countershaft and secondary shaft locknuts have left hand threads 21 Stake each locknut into its shaft using a 3 5 mm punch 22 Install the pitot flange A on the m...

Page 848: ...ange switch to N position NOTE The transmission range switch clicks in N position 28 Set the control shaft A to the N position by turning it NOTE Be careful not to squeeze the end of the control shaft...

Page 849: ...it with the bolts Take care not to move the transmission range switch when tightening the bolts 30 Install the transmission range switch cover C install the harness clamp D on the clamp bracket E ins...

Page 850: ...ER CARRIER BEARING BEARING OUTER RACE THRUST WASHER A B C A 1 Install both axles and place the differential assembly on V blocks A 2 Check the backlash of the pinion gears B with a dial indicator C 3...

Page 851: ...oss pattern Attachment 40 x 50 mm 07LAD PW50601 NOTE The bearing and outer race should be replaced as a set Inspect and adjust the bearing preload whenever the bearing is replaced Check the bearing fo...

Page 852: ...07GAD PG40101 or 07GAD PG40100 Oil seal driver attachment 07JAD PH80101 1 Remove the differential assembly 2 Remove the oil seal A from the transmission housing B 3 Remove the oil seal A from the tor...

Page 853: ...d after replacing the bearing and outer race Coat all parts with ATF during installation 1 Remove the bearing outer race from the transmission housing by heating the housing to about 212 F 100 C with...

Page 854: ...212 F 100 C with a heat gun E Do not heat the housing in excess of 212 F 100 C NOTE Let the transmission housing cool to room temperature before adjusting the bearing preload 2 Replace the tapered rol...

Page 855: ...dowel pins C on the torque converter housing D Align the spring pin on the control shaft E with the transmission housing groove 8 Install the transmission housing F with the transmission hangers G and...

Page 856: ...mm 0 081 in T 41439 PX4 700 2 01 mm 0 083 in U 41440 PX4 700 2 15 mm 0 085 in A 41441 PK4 000 2 20 mm 0 087 in B 41442 PK4 000 2 25 mm 0 089 in C 41443 PK4 000 2 30 mm 0 091 in D 41444 PK4 000 2 35 mm...

Page 857: ...ent 14 365 ATF Temperature Sensor Replacement 14 366 ATF Level Check 14 367 ATF Replacement 14 368 Transmission Removal 14 369 Drive Plate Removal and Installation 14 378 Transmission Installation 14...

Page 858: ...acement 14 440 Mainshaft Disassembly Inspection and Reassembly 14 441 4th 5th Clutch Clearance Inspection 14 442 Mainshaft Sealing Ring Replacement 14 443 Countershaft Disassembly Inspection and Reass...

Page 859: ...ment 78 x 80 mm 1 07SAZ 001000A Backprobe Set 2 07XAA 001030A Engine Support Fixture 1 07YAJ S3V0100 Preload Inspection Tool 1 07ZAA S0XA100 Cable Eyebolt Assembly 1 07ZAE PRP0100 Clutch Compressor At...

Page 860: ...fuel and emissions DTCs A T DTCs and freeze data 4 If there is a fuel and emissions DTC first check the fuel and emissions system as indicated by the DTC except for DTC P0700 DTC P0700 means there is...

Page 861: ...g and short blinks One long blink equals 10 short blinks Add the long and short blinks together to determine the code 3 Record all fuel and emissions DTCs and A T DTCs 4 If there is a fuel and emissio...

Page 862: ...side until it touches the end of the wire terminal 5 If you cannot get to the wire side of the connector or the wire side is sealed disconnect the connector and use the tester probe to probe the conne...

Page 863: ...the No 13 fuse in the passenger s under dash fuse relay box for more than 10 seconds If you do you need to do the following Get the customer s radio and navigation if equipped anti theft code and wri...

Page 864: ...C see page 14 334 P0778 23 Blinks ON A T clutch pressure control solenoid valve B see page 14 336 P0780 45 Blinks ON Mechanical problem in hydraulic system see page 14 338 P0798 29 Blinks ON A T clutc...

Page 865: ...he problem When you turn the ignition switch ON II the D indicator comes on stays on or never comes on at all A problem in the D indicator circuit Check the D indicator circuit see page 14 399 Shift l...

Page 866: ...orque down the main valve body This will result in ATF pump seizure if not detected Use the proper tools Install the main seal flush with the torque converter housing If you push it into the torque co...

Page 867: ...ulator defective 5th clutch defective Reverse gears worn or damaged Check the line pressure and 5th clutch pressure Check for a missing shift fork bolt on the shift fork shaft Check the ATF strainer f...

Page 868: ...ot detected Use the proper tools Poor acceleration flares on starting off in D and D3 stall speed high in 2 2nd clutch defective Check the 2nd clutch pressure Inspect the clutch piston and O rings Che...

Page 869: ...ATF cooler lines for leakage and loose connections If necessary flush the ATF cooler lines Vehicle moves in N 1 2 3 4 5 6 7 8 9 10 11 12 Excessive ATF Foreign material in separator plate orifice Relie...

Page 870: ...iscs and plates for wear and damage If the discs and plates are worn or damaged replace them as a set If they are OK adjust the clutch end plate clearance Late shift after shifting from N to R 1 2 3 4...

Page 871: ...check the shift solenoid valve for seizure Excessive shock or flares on all upshifts and downshifts 1 2 3 4 5 6 A T clutch pressure control solenoid valves A and B defective Input shaft mainshaft spe...

Page 872: ...fective 4th clutch defective Check the D indicator and check for loose connectors Inspect the O rings and check the shift solenoid valve for seizure Check for clogged orifice in the clutch transmissio...

Page 873: ...Joint in shift cable and transmission or body worn Check the D indicator and check for loose connectors Inspect the transmission range switch If the transmission range switch is faulty replace it If t...

Page 874: ...efective Lock up shift valve defective Lock up control valve defective Check the D indicator and check for loose connectors Inspect the A T clutch pressure control solenoid valve body gasket for wear...

Page 875: ...verter housing The main valve body contains the manual valve the modulator valve the shift valve C the shift valve D the kick down valve the servo control valve the torque converter check valve the re...

Page 876: ...h 4th 3rd 2nd and 1st on deceleration to stop The lock up mechanism operates in 3rd 4th and 5th gear D3 DRIVE 1st through 3rd Used for rapid acceleration at highway speeds and general driving up hill...

Page 877: ...hydraulic pressure through the secondary shaft by a circuit connected to the internal hydraulic circuit The 3rd clutch engages disengages 3rd gear and is located at the end of the countershaft just be...

Page 878: ...AR COUNTERSHAFT 3RD GEAR COUNTERSHAFT 1ST GEAR DIFFERENTIAL ASSEMBLY FINAL DRIVEN GEAR SECONDARY SHAFT 1ST GEAR 1ST CLUTCH 2ND CLUTCH SECONDARY SHAFT 2ND GEAR SECONDARY SHAFT IDLER GEAR SECONDARY SHAF...

Page 879: ...ar is splined with the mainshaft and rotates with the mainshaft Gears on the countershaft Final gear is integral with the countershaft 1st gear 4th gear 2nd gear and park gear are splined with the cou...

Page 880: ...park gear Engine power transmitted from the torque converter drives the mainshaft 3rd gear the countershaft 3rd gear and the secondary shaft idler gear but hydraulic pressure is not applied to the cl...

Page 881: ...ower flow when accelerating is as follows Hydraulic pressure is applied to the 1st clutch then the 1st clutch engages the secondary shaft 1st gear with the secondary shaft by the one way clutch Hydrau...

Page 882: ...g is as follows Hydraulic pressure is applied to the 1st clutch and the 1st hold clutch Rolling resistance from the road surface goes through the front wheels to the final drive gear then to the secon...

Page 883: ...selected from the 1st 2nd 3rd 4th and 5th gears according to conditions such as the balance between the throttle opening engine loading and vehicle speed Hydraulic pressure is applied to the 1st clut...

Page 884: ...the 2nd clutch engages the secondary shaft 2nd gear with the secondary shaft The mainshaft 3rd gear drives the secondary shaft via the countershaft 3rd gear and secondary shaft idler gear The seconda...

Page 885: ...ONE WAY CLUTCH Hydraulic pressure is applied to the 3rd clutch then the 3rd clutch engages the countershaft 3rd gear with the countershaft The mainshaft 3rd gear drives the countershaft 3rd gear and t...

Page 886: ...ied to the 4th clutch then the 4th clutch engages the mainshaft 4th gear with the mainshaft The mainshaft 4th gear drives the countershaft 4th gear and the countershaft Power is transmitted to the fin...

Page 887: ...t 5th gear while the shift lever is in the forward range D D3 2 and 1 position Hydraulic pressure is also applied to the 5th clutch then the 5th clutch engages the mainshaft 5th gear with the mainshaf...

Page 888: ...selector with the countershaft reverse gear while the shift lever is in the R position Hydraulic pressure is also applied to the 5th clutch then the 5th clutch engages the mainshaft reverse gear with...

Page 889: ...rature Sensor Signal 3rd Clutch Transmission Fluid Pressure Switch Signal 4th Clutch Transmission Fluid Pressure Switch Signal Self diagnosis Fail safe Function Communication and Output Function Shift...

Page 890: ...INPUT SHAFT MAINSHAFT SPEED SENSOR 3RD CLUTCH TRANSMISSION FLUID PRESSURE SWITCH SHIFT SOLENOID VALVE C TORQUE CONVERTER CLUTCH SOLENOID VALVE A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C 4TH CLUTCH T...

Page 891: ...gine coolant temperature sensor signal data Correction of cruise control signal data Judgment of Controlling Area Frequency Divider Input Shaft Mainshaft Speed Sensor Signal Output Shaft Countershaft...

Page 892: ...OFF Stays in 1st ON ON ON Shifting gears between 1st and 2nd ON ON ON Stays in 2nd ON ON OFF Shifting gears between 2nd and 3rd OFF ON OFF Stays in 3rd OFF ON ON D Shifting gears between 3rd and 4th...

Page 893: ...ble to automatically select the most suitable gear according to the magnitude of a gradient When the PCM determines that the vehicle is going down a hill in the D and D3 positions the shift up speed f...

Page 894: ...eedback A T Clutch Pressure Control Solenoid Valves A B and C Engine Coolant Temperature Sensor Signal Input Shaft Mainshaft Speed Sensor Signal 3rd Clutch Transmission Fluid Pressure Switch Signal Ou...

Page 895: ...l Lock up Control Lock up ON OFF control Lock up condition control Input Shaft Mainshaft Speed Sensor Signal Torque Converter Clutch Solenoid Valve Output Shaft Countershaft Speed Sensor Signal The to...

Page 896: ...ON SWITCH A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C SHIFT SOLENOID VALVE A SHIFT SOLENOID VALVE B SHIFT SOL...

Page 897: ...nal detected from output shaft countershaft speed sensor and sent to speedometer and odometer Depending on vehicle speed Pulsing signal A10 BRN SCS Detects service check signal With ignition switch ON...

Page 898: ...re control solenoid valve A power supply positive electrode With ignition switch ON II Pulsing signal B18 GRN LS B A T clutch pressure control solenoid valve B power supply negative electrode B19 BLU...

Page 899: ...ar P R and N 0 V in these positions D in 4th and 5th gear D3 GRN SH C Shift solenoid valve C control Battery voltage in these positions 1 D and D3 in 1st 3rd and 5th gear 0 V in these positions 2 D an...

Page 900: ...About 0 V D11 RED NM Input shaft mainshaft speed sensor input Depending on vehicle speed Pulsing signal When engine is stopped About 0 V D12 WHT NMSG Input shaft mainshaft speed sensor ground D13 BLU...

Page 901: ...D VALVE B The valve body includes the main valve body the regulator valve body the servo body and the accumulator body The ATF pump is driven by splines on the left end of the torque converter which i...

Page 902: ...the modulator valve the shift valve C the shift valve D the servo control valve the cooler check valve the torque converter check valve the reverse CPC valve the lock up shift valve the relief valve...

Page 903: ...valve and the regulator valve moves to the left side According to the level of the hydraulic pressure through B the position of the regulator valve changes and the amount of fluid from B through torqu...

Page 904: ...1ST ACCUMULATOR 2ND ACCUMULATOR END COVER 3RD ACCUMULATOR The servo body is on the main valve body It contains the servo valve the shift valve A the shift valve B CPC valves A and B The top accumulato...

Page 905: ...PCM controls one of the shift solenoid valves to move the position of the shift valve This movement switches the port of the CPC and line pressure Line pressure is then applied to the clutch and the...

Page 906: ...T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X SA 5J...

Page 907: ...4 LOCK UP SHIFT VALVE 95 25 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID...

Page 908: ...SWITCH LA 94 LOCK UP SHIFT VALVE 95 25 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SH...

Page 909: ...CCUMULATOR 4TH CLUTCH TRANSMISSION FLUID PRESSURE SWITCH LA94 LOCK UP SHIFT VALVE 95 25 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C A T CLUTCH PRESSURE CO...

Page 910: ...CH TRANSMISSION FLUID PRESSURE SWITCH LA 94 LOCK UP SHIFT VALVE 95 25 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VAL...

Page 911: ...C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X S...

Page 912: ...ID VALVE A A T CLUTCH PRESSURE CONTROL SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D...

Page 913: ...VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE...

Page 914: ...ENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X SA 5J 5G 50X 5E 5F SHIFT VALVE B 1...

Page 915: ...CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X SA 5J 5...

Page 916: ...VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X SA 5J 5G 50X 5E 5F SHIFT VALVE B 15 SHIF...

Page 917: ...SOLENOID VALVE C A T CLUTCH PRESSURE CONTROL SOLENOID VALVE B SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 C...

Page 918: ...A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X SA 5J 5G 50X 5E 5F SHIFT VALVE B 15 SHIFT VALVE D 40 H4X 93 MAINSHAFT COUNTERSHAFT SECONDARY SHAFT 4A AX 5A 5E 20 A...

Page 919: ...NSMISSION FLUID PRESSURE SWITCH 2ND ACCUMULATOR 4TH CLUTCH TRANSMISSION FLUID PRESSURE SWITCH LA 94 LOCK UP SHIFT VALVE 95 25 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONTROL S...

Page 920: ...LENOID VALVE B SHIFT SOLENOID VALVE C SHIFT SOLENOID VALVE A 6 6 CPC VALVE A CPC VALVE B 5D 4A SHIFT VALVE C SHIFT VALVE E 4C 1 CPC VALVE C H3X SA 5J 5G 50X 5E 5F SHIFT VALVE B 15 SHIFT VALVE D 40 H4X...

Page 921: ...CH TRANSMISSION FLUID PRESSURE SWITCH 2ND ACCUMULATOR 4TH CLUTCH TRANSMISSION FLUID PRESSURE SWITCH LA94 LOCK UP SHIFT VALVE 95 25 A T CLUTCH PRESSURE CONTROL SOLENOID VALVE A A T CLUTCH PRESSURE CONT...

Page 922: ...of the torque converter through a fluid passage causing the torque converter clutch piston to be held against the torque converter cover As this takes place the mainshaft rotates at the same speed as...

Page 923: ...etween the torque converter cover and the torque converter clutch piston is drained off and fluid entering from the chamber between the pump and stator exerts pressure through the torque converter clu...

Page 924: ...FT TORQUE CONVERTER CHECK VALVE The torque converter clutch solenoid valve is turned OFF by the PCM The lock up shift valve receives LC pressure LA on the left side and modulator pressure 6 on the rig...

Page 925: ...ft valve then the lock up shift valve is moved in the left side to switch the port leading torque converter pressure to the right side of the torque converter Torque converter pressure 91 is applied t...

Page 926: ...CK UP SHIFT VALVE LA 94 58 96 X 95 93 HX MAINSHAFT COUNTERSHAFT SECONDARY SHAFT TORQUE CONVERTER CHECK VALVE When the vehicle speed further increases the PCM controls A T clutch pressure control solen...

Page 927: ...RTRAIN CONTROL MODULE PCM To 12V IGNITION SWITCH No 6 15A No 1 15A WHT RED No 41 120A REGULATOR 5V D5 D9 1 D15 D3 2 UNDER HOOD FUSE RELAY BOX D14 D8 D6 A14 TRANSMISSION RANGE SWITCH 1 2 N R P D3 N R 5...

Page 928: ...HAFT COUNTERSHAFT SPEED SENSOR MAINFOLD ABSOLUTE PRESSURE SENSOR INPUT SHAFT MAINSHAFT SPEED SENSOR THROTTLE POSITION SENSOR ENGINE COOLANT TEMPERATURE SENSOR ATF TEMPERATURE SENSOR BRAKE PEDAL POSITI...

Page 929: ...the ATF temperature sensor harness 3 Measure ATF temperature sensor resistance at the sensor connector Go to step 4 Replace the ATF temperature sensor see page 14 366 4 Turn the ignition switch ON II...

Page 930: ...Turn the ignition switch OFF 9 Disconnect PCM connector C 31P 10 Check for continuity between PCM connector terminal C24 and body ground Repair short to ground in the wire between PCM connector termi...

Page 931: ...e speed sensor usually means a hydraulic system problem caused the DTC 1 Turn the ignition switch ON II 2 Check whether the scan tool or the HDS indicates the code for the throttle position TP sensor...

Page 932: ...the ignition switch ON II 13 Measure the voltage between input shaft mainshaft speed sensor connector terminals No 2 and No 3 Go to step 19 Go to step 14 14 Measure the voltage between PCM connector t...

Page 933: ...connectors If necessary substitute a known good PCM and recheck only if the code resets after being cleared 19 Connect the input shaft mainshaft speed sensor connector 20 Measure the voltage between P...

Page 934: ...connector 5 Turn the ignition switch ON II 6 Measure the voltage between output shaft countershaft speed sensor connector terminal No 1 and body ground Go to step 7 Go to step 14 7 Turn the ignition...

Page 935: ...n the PCM connectors If necessary substitute a known good PCM and recheck 14 Measure the voltage between PCM connector terminal C19 and body ground Repair open in the wire between PCM connector termin...

Page 936: ...vehicle and make sure it is securely supported 21 Set the parking brake and block both rear wheels securely 22 Start the engine then shift to D position and let the wheels spin the vehicle 23 Measure...

Page 937: ...e causes of any other DTCs have been corrected 2 Measure the 1st 2nd 3rd 4th and 5th clutch pressure see page 14 355 Go to step 3 Replace the transmission 3 Replace shift solenoid valve B see page 14...

Page 938: ...5 Go to step 3 Replace the transmission 3 Replace torque converter clutch solenoid valve see page 14 357 4 Replace A T clutch pressure control solenoid valve C see page 14 363 5 Clear the DTC with the...

Page 939: ...ect PCM connectors B 25P and D 16P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals D1 and B20 or B22 Repair short to power in the wire between PCM connector term...

Page 940: ...tween PCM connector terminal D1 and the torque converter clutch solenoid valve and between torque converter clutch solenoid valve connector terminal No 1 and ground G101 Replace the torque converter c...

Page 941: ...stance at the solenoid valve connector Go to step 3 Replace the A T clutch pressure control solenoid valve A see page 14 361 3 Disconnect PCM connector B 25P 4 Check for continuity between PCM connect...

Page 942: ...loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck Check for blown No 6 15A fuse in the driver s under dash fuse relay box If the fuse is OK repair open in...

Page 943: ...isconnect PCM connectors B 25P and D 16P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals D7 and B20 or B22 Repair short to power in the wire between PCM connecto...

Page 944: ...M connector terminal D7 and shift solenoid valve A and between shift solenoid valve A connector terminal No 1 and ground G101 Replace the shift solenoid valve A see page 14 359 11 Turn the ignition sw...

Page 945: ...isconnect PCM connectors B 25P and D 16P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals D2 and B20 or B22 Repair short to power in the wire between PCM connecto...

Page 946: ...M connector terminal D2 and shift solenoid valve B and between shift solenoid valve B connector terminal No 1 and ground G101 Replace the shift solenoid valve B see page 14 358 11 Turn the ignition sw...

Page 947: ...nnect PCM connectors B 25P and D 16P 3 Turn the ignition switch ON II 4 Measure the voltage between PCM connector terminals D3 and B20 or B22 Repair short to power in the wire between PCM connector te...

Page 948: ...connector terminal D3 and shift solenoid valve C and between shift solenoid valve C connector terminal No 1 and ground G101 Replace the shift solenoid valve C see page 14 359 11 Turn the ignition swit...

Page 949: ...d resistance at the solenoid valve connector Go to step 3 Replace the A T clutch pressure control solenoid valve B see page 14 361 3 Disconnect PCM connector B 25P 4 Check for continuity between PCM c...

Page 950: ...loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck Check for blown No 6 15A fuse in the driver s under dash fuse relay box If the fuse is OK repair open in...

Page 951: ...d valves A and B 1 Check whether the scan tool or the HDS indicates another code Perform the Troubleshooting Flowchart for the indicated code s Recheck for code P0780 after troubleshooting Go to step...

Page 952: ...id valve connector Go to step 3 Replace A T clutch pressure control solenoid valve C see page 14 363 3 Disconnect PCM connector B 25P 4 Check for continuity between PCM connector terminals B13 and bod...

Page 953: ...and B20 or B22 Check for loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck Check for blown No 6 15A fuse in the driver s under dash fuse relay box If the f...

Page 954: ...erminals D13 and B20 or B22 Go to step 7 Go to step 3 3 Turn the ignition switch OFF 4 Disconnect PCM connector D 16P 5 Disconnect the 3rd clutch transmission fluid pressure switch connector 6 Check f...

Page 955: ...d PCM and recheck Go to step 11 11 Turn the ignition switch OFF 12 Disconnect the 3rd clutch transmission fluid pressure switch connector 13 Turn the ignition switch ON II 14 Measure the voltage betwe...

Page 956: ...the wire between PCM connector terminal D6 and the transmission range switch or A T gear position indicator and check for an open in the wires between PCM connector terminals B20 and B22 and body gro...

Page 957: ...ar position indicator If the wire is OK check for loose terminal fit in the PCM connectors If necessary substitute a known good PCM and recheck 8 Shift to all positions other than D3 9 Measure the vol...

Page 958: ...the PCM connectors If necessary substitute a known good PCM and recheck 12 Shift to all positions other than 1 13 Measure the voltage between PCM connector terminals D15 and B20 or B22 Check for loose...

Page 959: ...2 Turn the ignition switch OFF 3 Check for continuity between PCM connector terminals B20 and body ground and between B22 and body ground Go to step 4 Repair open in the wire between PCM connector ter...

Page 960: ...air open in the wire between PCM connector terminal D8 and the transmission range switch Go to step 13 13 Shift to the 2 position 14 Measure the voltage between PCM connector terminals D14 and B20 or...

Page 961: ...e between PCM connector terminals B19 and B20 or B22 Go to step 7 Go to step 3 3 Turn the ignition switch OFF 4 Disconnect PCM connector B 25P 5 Disconnect the 4th clutch transmission fluid pressure s...

Page 962: ...p 11 11 Turn the ignition switch OFF 12 Disconnect the 4th clutch transmission fluid pressure switch connector 13 Turn the ignition switch ON II 14 Measure the voltage between the 4th clutch transmiss...

Page 963: ...DS indicates another code Perform the Troubleshooting Flowchart for the indicated code s Recheck for code P1750 after troubleshooting Go to step 2 2 Turn the ignition switch OFF 3 Replace the A T clut...

Page 964: ...lves A and B 1 Check whether the scan tool or the HDS indicates another code Perform the Troubleshooting Flowchart for the indicated code s Recheck for code P1751 after troubleshooting Go to step 2 2...

Page 965: ...it suddenly Make sure that the engine should not stall 4 Repeat the same test in the D3 2 and 1 position 5 Connect the HDS to the DLC A and go to the PGM FI data list then go to step 10 If you don t...

Page 966: ...m h 5th 4th 36 40 mph 58 61 km h 4th 3rd 17 19 mph 29 31 km h 2nd 1st 9 10 mph 15 17 km h Lock up OFF 76 80 mph 123 129 km h 5th 4th 65 68 mph 105 109 km h 4th 3rd 40 41 mph 64 67 km h 3rd 2nd 23 25 m...

Page 967: ...ositions NOTE Do not test stall speed for more than 10 seconds at a time Stall speed tests should be used for diagnostic purposes only Stall speed should be the same in D 2 1 and R positions Do not te...

Page 968: ...vel 2 Raise the vehicle and make sure it is securely supported 3 Allow all four wheels to rotate freely 4 Warm up the engine the radiator fan comes on then stop it and connect a tachometer 5 Connect t...

Page 969: ...d clutch pressure at the 3rd clutch pressure inspection hole D 15 Shift to the D position and measure 4th clutch pressure at the 4th clutch pressure inspection hole E then in about 15 seconds the tran...

Page 970: ...resistance is within the standard connect the No 2 terminal of the torque converter clutch solenoid valve connector to the battery positive terminal and connect the No 1 terminal to the battery negat...

Page 971: ...e resistance is within the standard connect the No 2 terminal of the shift solenoid valve B connector to the battery positive terminal and connect the No 1 terminal to the battery negative terminal A...

Page 972: ...attery negative terminal A clicking sound should be heard Replace shift solenoid valve A or C if no clicking sound is heard NOTE If shift solenoid valves A and C are replaced or removed at the same ti...

Page 973: ...clicking sound should be heard Remove A T clutch pressure control solenoid valves A and B if no sound is heard 5 Check the fluid passage of the A T clutch pressure control solenoid valves for dust and...

Page 974: ...oid valves A and B and the transmission housing 4 Place a new gasket B on the transmission housing then install the 8 x 18 mm ATF feed pipes C with their filter sides into the transmission housing 5 I...

Page 975: ...minal A clicking sound should be heard Remove A T clutch pressure control solenoid valve C if no sound is heard 5 Check the fluid passage of A T clutch pressure control solenoid valve C for dust and d...

Page 976: ...ounting surface and fluid passage of A T clutch pressure control solenoid valve C and the transmission housing 4 Install the 8 x 12 mm ATF feed pipe B with its filter side into the transmission housin...

Page 977: ...input shaft mainshaft speed sensor in the end cover Do not allow dust or foreign particles to enter the transmission 4 Check the connector for rust dirt or oil then connect the connector securely 1 D...

Page 978: ...witch then install a new one with a new sealing washer C Tighten the switch on the metal part not the plastic part 4 Reconnect the connector making sure there is no water oil dust or other foreign par...

Page 979: ...sion lower front mount clear the subframe 3 Remove the transmission lower front mount 4 Disconnect the connector A from the ATF temperature sensor 5 Remove the bolts securing the sensor harness clamp...

Page 980: ...Remove the dipstick and check the fluid level It should be between the upper mark B and lower mark C 6 If the level is below the lower mark check for fluid leaks at the transmission hose and line joi...

Page 981: ...vehicle 2 Park the vehicle on the level ground and turn the engine off 3 Remove the ATF filler bolt and the drain plug A and drain the automatic transmission fluid ATF NOTE If a cooler flusher is used...

Page 982: ...then fix the hood in a vertical position using the support rod 3 Remove the engine covers 4 Remove the intake air duct resonator cover and air cleaner housing assembly 5 Disconnect the battery negati...

Page 983: ...Check for any signs of leakage at the hose joints 15 Remove the starter cables A from the starter B then remove the starter 16 Remove the harness clamps B from the brackets D then disconnect the conn...

Page 984: ...or then remove the harness clamp C from the bracket D 22 Disconnect the connector from the output shaft countershaft speed sensor E 23 Remove the bolts securing the harness cover F harness clamp G and...

Page 985: ...ront cylinder head with a spacer D and the 10 x 1 25 mm bolt E Attatch the rear arm F the rear cylinder head with the 8 x 1 25 mm bolt G 29 Remove the oxygen sensor connectors B from their connector b...

Page 986: ...x 14 mm bolt A and nut B on the shift cable cover C then reinstall the shift cable cover to the torque converter housing If you don t do this the bolt head of the cable cover may prevent you from remo...

Page 987: ...arbox mounting bolt B and nut C 41 Remove the steering gearbox mounting bolts A and nut B and remove the stiffener C 42 Remove the rear mount mounting bolts D 43 Unclamp the power steering fluid line...

Page 988: ...ble through the Honda Tool and Equipment Program It will also work with most commercially available transmission jack 47 Line up the slots in the arms with the bolt holes on the corner of the jack bas...

Page 989: ...52 Pry the left driveshaft out of the differential and the right driveshaft from the intermediate shaft see page 16 3 53 Move the left driveshaft to the front side Coat all precision finished surfaces...

Page 990: ...the transmission jack NOTE If the torque converter is stuck to the drive plate pull it toward the transmission housing through the starter opening 59 Remove the shift cable cover then remove the torq...

Page 991: ...val and Installation 12 x 1 25 mm 74 N m 7 5 kgf m 54 lbf ft A B 1 Remove the drive plate A and washer B from the engine crankshaft 2 Install the drive plate and washer on the engine crankshaft and ti...

Page 992: ...cooler see page 14 388 2 Install the transmission lower mounts 3 Install the torque converter A on the mainshaft B with the new O ring C 4 Install the 14 mm dowel pin D and 10 mm dowel pin E in the t...

Page 993: ...he specified torque then to the final torque in a crisscross pattern After tightening the last bolt check that the crankshaft rotates freely 10 Install the torque converter cover D 11 Tighten the cran...

Page 994: ...ontacts the transmission differential with solvent or carburetor cleaner and dry with compressed air Turn the right and left steering knuckle fully outward and slide the left driveshaft into the diffe...

Page 995: ...ft 10 x 1 25 mm 59 N m 6 0 kgf m 43 lbf ft B 10 x 1 25 mm 58 N m 5 9 kgf m 43 lbf ft C A 10 x 1 25 mm 59 N m 6 0 kgf m 43 lbf ft 18 Install the transmission lower mount nuts 19 Install the power steer...

Page 996: ...Do not bend the shift cable excessively 26 Install the lock bolt D with a new lock washer E then bend the lock washer tab against the bolt 27 Install the shift cable cover F then install the shift ca...

Page 997: ...2 N m 2 2 kgf m 16 lbf ft A B C 32 Install the splash shield 33 Install the transmission housing mounting bolts 34 Install and tighten the nut A on the front mount B and install the ground cable C to...

Page 998: ...ect the connectors to the torque converter solenoid valve A and the shift solenoid valve B 41 Connect the connectors to the A T clutch pressure control solenoid valves A and B then install the harness...

Page 999: ...Connect the ATF cooler hoses A to the ATF cooler lines B see page 14 389 Clamp the ATF cooler hose with the clamp C on the starter by aligning the white dot D on the hose with the clamp 46 Install th...

Page 1000: ...rt rod of the hood to the proper location and secure the windshield washer reservoir opening with the bolt 58 Start the engine and let it reach normal operating temperature the radiator fan comes on w...

Page 1001: ...amp Securely clamp the opposite end of the drain hose to a bucket D or floor drain 7 With the water and air valves A off attach the water and air supplies to the flusher Hot water if available 8 Turn...

Page 1002: ...for 30 seconds or until approximately 0 95 1 0 US qt is discharged 18 Remove the drain hose and reconnect the cooler return hose to the transmission 19 Refill the transmission with ATF to the proper...

Page 1003: ...Shift the transmission into the N position 3 Remove the nut A securing the shift cable end B then separate the shift cable C from the shift lever assembly D 4 Rotate the socket holder E on the shift c...

Page 1004: ...2004 models see page 23 20 and the precautions and procedures see page 23 21 in the SRS before performing repairs or service 1 Install the shift lever assembly on the steering column 2 Turn the igniti...

Page 1005: ...2 lbf ft DETENT SPRING SHIFT LOCK EXTENSION SHIFT LOCK CUSHION SHIFT LOCK SOLENOID PLUNGER PLUNGER SPRING 4 mm SCREW 3 N m 0 3 kgf m 2 lbf ft WASHER SHIFT LEVER KNOB 9 N m 0 9 kgf m 7 lbf ft Apply si...

Page 1006: ...wheels securely 3 Remove the steering column covers see page 17 25 4 Shift the transmission into the N position 5 Remove the nut A securing the shift cable end B then separate the shift cable C from t...

Page 1007: ...e control shaft C Do not bend the shift cable excessively 13 Install the lock bolt D with a new lock washer E then bend the lock washer tab against the bolt head 14 Install the shift cable cover F the...

Page 1008: ...e C from the shift lever assembly D 4 Rotate the socket holder E on the shift cable counterclockwise a quarter turn then slide the holder to remove the shift cable from the shift cable bracket F NOTE...

Page 1009: ...hift cable by twisting the shift cable guide H 10 Verify that the shift cable end A is properly installed on the mounting stud B 11 If improperly installed remove the shift cable from the shift cable...

Page 1010: ...n Index A T GEAR POSITION INDICATOR POWERTRAIN CONTROL MODULE PCM TRANSMISSION RANGE SWITCH D Indicator Circuit Troubleshooting page 14 399 Indicator Input Test page 14 402 Indicator Bulb Replacement...

Page 1011: ...U BLK WHT RED BLK RED BLU BRN BLU WHT VSS A9 OUT BLU YEL E ST A No 9 10A IG1 BAT CONTROL YEL IND R 1 2 UNIT CRUISE BLK G101 RED WHT PNK GRY BLK BLU WHT RED YEL GRN BLU BRN BRN BLU RED RED BLK WHT BLK...

Page 1012: ...n switch OFF 8 Reconnect PCM connector A 32P 9 Turn the ignition switch ON II 10 Shift to any position other than D 11 Measure the voltage between PCM connector terminal D9 and body ground Faulty PCM...

Page 1013: ...voltage between PCM connector terminals B1 and B22 and between B9 and B20 Go to step 19 Repair open or short in the wire between PCM connector terminal B1 or B9 and the PGM FI main relay 19 Turn the...

Page 1014: ...ntinuity between PCM connector terminal A14 and body ground Repair open in the wire between PCM connector terminal A14 and the gauge assembly Check for loose terminal fit in the PCM connectors Check t...

Page 1015: ...ground There should be continuity Poor ground G503 An open in the wire B22 RED BLK Headlights ON Check for voltage to ground There should be battery voltage Blown No 10 15A fuse in the passenger s un...

Page 1016: ...1 Transmission Range Switch Continuity Check N 1 Remove the transmission range switch connector A from the connector bracket B then disconnect the connector 2 Check for continuity between the terminal...

Page 1017: ...or bracket B then disconnect the connector 4 Remove the harness clamp C from its bracket D 5 Remove the clamp from the clamp bracket on the transmission housing and remove the harness holder A from th...

Page 1018: ...0 Connect the transmission range switch connector A then install it on the connector bracket B 11 Install the harness clamp C on its bracket D 12 Turn the ignition switch ON II Move the shift lever th...

Page 1019: ...ew the SRS component locations 2002 model see page 23 19 2003 2004 models see page 23 20 and the precautions and procedures see page 23 21 in the SRS before performing repairs or service 1 Remove the...

Page 1020: ...RING LOCK ASSEMBLY KEY INTERLOCK SOLENOID KEY INTERLOCK SWITCH Shift Lock System Circuit Troubleshooting page 14 409 Input Test page 14 414 Shift Lock System Circuit Troubleshooting page 14 409 Test p...

Page 1021: ...A12 YEL BLK PG POWERTRAIN CONTROL MODULE PCM ILU A28 WHT RED BLK BLU ATP P ILU B12 B22 GRN 2 1 YEL IG1 BAT IGNITION SWITCH No 9 10A UNDER HOOD FUSE RELAY BOX No 42 50A No 41 120A No 47 20A BATTERY WHT...

Page 1022: ...ontrol unit driver s connectors If necessary substitute a known good multiplex control unit driver s and recheck Go to step 5 5 Turn the ignition switch OFF and disconnect the battery negative termina...

Page 1023: ...replace the TPS Go to step 15 15 Turn the ignition switch OFF 16 Disconnect PCM connector C 31P 17 Check for continuity between TPS connector terminal No 1 and body ground and between terminal No 3 an...

Page 1024: ...relay box 22 Connect the battery positive terminal to shift lock solenoid connector terminal No 1 and connect the battery negative terminal to the terminal No 2 NOTE Do not connect the terminal No 2 t...

Page 1025: ...oid switch Replace the ignition key cylinder steering lock assembly 5 Measure the voltage between the terminal No 7 and body ground Go to step 6 Check for a blown No 47 20A fuse in the under hood fuse...

Page 1026: ...ector terminal No 3 and the key switch connector terminal No 5 9 Check for continuity between park pin switch connector terminal No 1 and body ground Check for a loose key switch connector and park pi...

Page 1027: ...input tests If a test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK go to step 4 A2 Under all conditions Check for continuity to ground There s...

Page 1028: ...erlock solenoid is not available separately SRS components are located in this area Review the SRS component locations 2002 model see page 23 19 2003 2004 models see page 23 20 and the precautions and...

Page 1029: ...ift cable end B then separate the shift cable C from the shift lever assembly D 4 Disconnect the shift lock solenoid connector A and the park pin switch connector B 5 Remove the three bolts C securing...

Page 1030: ...service 1 Remove the steering column covers see page 17 25 2 Disconnect the park pin switch connector 3 Shift the shift lever into the P position then check for continuity between the terminals No 1...

Page 1031: ...ENOID VALVE C ATF FILTER LINE BRACKET ATF FILTER LINE A T WIRE HARNESS GROUND TERMINAL CONNECTOR BRACKET SWITCH COVER ATF TEMPERATURE SENSOR ATF PASSAGE BODY A T CLUTCH PRESSURE CONTROL SOLENOID VALVE...

Page 1032: ...s clamp then remove the transmission range switch 6 Remove the harness clamp bracket ATF cooler line bolts two and lines 7 Remove the line bolt the ATF hose and the ATF filter line 8 Remove the ATF fi...

Page 1033: ...t 17 Remove the mainshaft 3rd gear A secondary shaft idler gear B and park gear C with a puller D 18 Remove the park pawl park pawl spring park pawl shaft and stop shaft 19 Remove the park lever from...

Page 1034: ...ver 07749 0010000 Attachment 22 x 24 mm 07746 0010800 1 Remove the oil seal A from the end cover B 2 Install the new oil seal flush to the end cover with the special tools Driver 07749 0010000 Attachm...

Page 1035: ...the end cover D 2 Install the new O ring E over the ATF feed pipe 3 Install ATF feed pipe in the end cover with aligning the feed pipe tabs with the indentations in the end cover 4 Install the new O...

Page 1036: ...TORQUE CONVERTER HOUSING DIFFERENTIAL ASSEMBLY COUNTERSHAFT SUBASSEMBLY SECONDARY SHAFT SUBASSEMBLY COUNTERSHAFT 5TH GEAR REVERSE SELECTOR HUB REVERSE SELECTOR COUNTERSHAFT REVERSE GEAR COUNTERSHAFT...

Page 1037: ...control shaft 6 Install the special tool over the mainshaft then remove the transmission housing D NOTE If the top arm of your housing puller is too short replace it with Housing puller arm 205 mm T...

Page 1038: ...ransmission housing expand each snap ring with the snap ring pliers then push the bearing out NOTE Do not remove the snap rings unless it s necessary to clean the grooves in the housing 2 Install the...

Page 1039: ...CK VALVE SPRING ACCUMULATOR BODY 6 x 1 0 mm Seven Bolts SERVO SEPARATOR PLATE DOWEL PINS Two Pins SERVO BODY 6 x 1 0 mm Five Bolts 6 x 1 0 mm Seven Bolts O RING ATF STRAINER SERVO DETENT BASE ATF FEED...

Page 1040: ...ove the regulator separator plate and dowel pins 2 9 Remove the accumulator body seven bolts 10 Unhook the detent spring from the detent arm then remove the detent arm shaft detent arm and control sha...

Page 1041: ...y it with compressed air 4 Roll up half a sheet of ATF soaked 600 paper and insert it in the valve bore of the sticking valve Twist the paper slightly so that it unrolls and fits the bore tightly then...

Page 1042: ...age 14 433 servo body see page 14 434 and top accumulator body see page 14 435 Refer to the following valve cap illustrations and install each valve cap so the end shown facing up will be facing the o...

Page 1043: ...DOWN VALVE CHECK BALL VALVE CAP 1 Clean all parts thoroughly in solvent or carburetor cleaner and dry them with compressed air Blow out all passages 2 Do not use a magnet to remove the check ball it...

Page 1044: ...n valve spring 0 8 0 031 6 6 0 260 49 1 1 933 21 7 Modulator valve spring 1 6 0 063 10 4 0 409 33 5 1 319 9 8 Relief valve spring 1 2 0 047 11 1 0 437 39 0 1 535 9 9 Lock up shift valve spring 0 9 0 0...

Page 1045: ...Pump Inspection A B C D A B B D A C 1 Install the ATF pump drive gear A driven gear B and ATF pump driven gear shaft C in the main valve body D Lubricate all parts with ATF and install the ATF pump dr...

Page 1046: ...or damaged 4 Hold the regulator spring cap in place while removing the stop bolt The regulator spring cap is spring loaded Once the stop bolt is removed release the spring cap slowly so it does not p...

Page 1047: ...r cleaner and dry them with compressed air Blow out all passages 2 Check all valves for free movement If any fail to slide freely refer to Valve Body Repair see page 14 428 3 Replace the valve body as...

Page 1048: ...with compressed air Blow out all passages 2 Check all valves for free movement If any fail to slide freely refer to Valve Body Repair see page 14 428 3 Replace the valve body as an assembly if any pa...

Page 1049: ...R BODY COVER O RING 1 Do not use a magnet to remove the check balls it may magnetize the balls 2 Clean all parts thoroughly in solvent or carburetor cleaner and dry them with compressed air Blow out a...

Page 1050: ...sembly Inspection and Reassembly END COVER O RING 3RD ACCUMULATOR PISTON 3RD ACCUMULATOR BODY COVER SNAP RING 1 Clean all parts thoroughly in solvent or carburetor cleaner and dry them with compressed...

Page 1051: ...25 40 mm 07736 A01000B or 07736 A01000A Driver 07749 0010000 Attachment 62 x 68 mm 07746 0010500 Attachment 72 x 75 mm 07746 0010600 1 Remove the mainshaft bearing and oil seal with the special tools...

Page 1052: ...0010000 Attachment 62 x 68 mm 07746 0010500 1 Remove the countershaft bearing A with the special tools and a commercially available 3 8 16 slide hammer B 2 Install the ATF guide plate A 3 Install the...

Page 1053: ...Shaft Oil Seal Replacement A B 07749 0010000 07746 0010800 Driver 07749 0010000 Attachment 22 x 24 mm 07746 0010800 1 Remove the oil seal A from the torque converter housing B 2 Install the new oil se...

Page 1054: ...RUST NEEDLE BEARING 1 Lubricate all parts with ATF during assembly 2 Check the clearance of the 4th 5th clutch assembly 3 Inspect the thrust needle bearing and the needle bearing for galling and rough...

Page 1055: ...ly B then measure the clearance between the clutch guide E and the 5th gear collar with a feeler gauge F in at least 3 places Use the average as the actual clearance 4 If the clearance is out of stand...

Page 1056: ...they are worn distorted or damaged 1 For a better fit squeeze sealing rings together slightly before installing them 2 Apply ATF to the new sealing rings then install them on the mainshaft 3 After ins...

Page 1057: ...LLAR 35 x 47 x 7 8 mm 1 Remove the locknut and take off components down to the reverse selector hub 2 Remove the reverse selector hub 4th gear and 1st gear see page 14 445 3 Check the bearing on the 3...

Page 1058: ...g the countershaft NOTE Some reverse selector hubs are not press fitted and can be removed without using a press 2 Remove the needle bearing snap ring 35 x 47 x 7 8 mm distance collar 31 mm cotters 35...

Page 1059: ...protector B between the countershaft and press to prevent damaging the countershaft 4 Stop pressing the countershaft when the 4th gear contacts the 1st gear C 5 Install the 31 mm cotters 35 x 47 x 45...

Page 1060: ...x 68 mm 07746 0010500 NOTE Check the bearing for wear and rough movement If the bearing is OK removal is not necessary 1 Remove the ball bearing A from the 3rd clutch with a commercially available be...

Page 1061: ...LUTCH HUB 1ST CLUTCH HUB 1 Remove the locknut and disassemble the shaft and gears 2 Inspect the thrust needle bearing and needle bearing for galling and rough movement 3 Check the clearance of the sec...

Page 1062: ...snap ring H on the secondary shaft I 3 Measure the clearance between the 38 x 56 5 mm splined washer E and 32 mm cotters F with a feeler gauge J in at least three places Use the average as the actual...

Page 1063: ...on the 2nd gear E 9 Hold the 27 x 47 x 5 mm thrust washer G against the clutch assembly A and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear E Use the average...

Page 1064: ...mm 07GAD SD40101 1 Check the bearing for wear damage and rough movement If the bearing is worn or damaged go to step 2 2 Place the secondary shaft idler gear in a vise with soft jaws 3 Remove the bear...

Page 1065: ...posite direction 2 If any problem occurs on the 1st gear one way clutch replace the 1st clutch hub C The 1st gear one way clutch is not available separately from the 1st clutch hub Driver 07749 001000...

Page 1066: ...07GAE PG40200 or 07GAE PG4020A 1 Remove the snap ring A then remove the clutch end plate the clutch discs and the plates with a screwdriver B 2 Remove the disc spring A from the 1st 3rd 4th and 5th cl...

Page 1067: ...et over an area of the spring retainer which is unsupported by the return spring the retainer may be damaged 7 Compress the spring until the snap ring can be removed 8 Remove the snap ring A Then remo...

Page 1068: ...Five Plates Standard thickness 1 6 mm 0 063 in 1ST CLUTCH PISTON CHECK VALVE CHECK VALVE CHECK VALVE 1 Inspect the clutch piston and clutch piston check valve If the clutch check valve is loose or stu...

Page 1069: ...valve is loose or stuck damaged replace the clutch piston 2 Check the spring retainer for wear and damage 3 Inspect the clutch discs clutch plates and clutch end plate for wear damage and discolorati...

Page 1070: ...CLUTCH PLATES Four Plates Standard thickness 2 3 mm 0 091 in CHECK VALVE 1 Inspect the clutch piston and clutch piston check valve If the clutch check valve is loose or stuck damaged replace the clut...

Page 1071: ...vent or carburetor cleaner and dry them with compressed air Blow out all passages Apply ATF to all parts before assembly 1 Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes 2 Inspect...

Page 1072: ...lutch clearance between the 1st hold clutch plate B and the top disc A with a feeler gauge C while pressing the 1st hold clutch plate B down Take measurements in at least three places and use the aver...

Page 1073: ...of the 2nd and 3rd clutches so the tool works on the clutch return spring C 12 If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring th...

Page 1074: ...of the clutch drum is free of dirt and other foreign particles 18 Starting with a clutch plate alternately install the clutch plates and discs Install the clutch end plate A with the flat side toward...

Page 1075: ...the average as the actual clearance 24 If the clearance is not within the service limit select a new clutch end plate from the following table NOTE If the thickest clutch end plate is installed but t...

Page 1076: ...60 PVG 003 3 0 mm 0 118 in 11 22561 PVG 003 3 1 mm 0 122 in 12 22562 PVG 003 3 2 mm 0 126 in 13 22563 PVG 003 3 3 mm 0 130 in 14 22564 PVG 003 3 4 mm 0 134 in 1 22561 P7T 003 2 1 mm 0 083 in 2 22562 P...

Page 1077: ...HECK VALVE SPRING ACCUMULATOR BODY 6 x 1 0 mm Seven Bolts SERVO SEPARATOR PLATE DOWEL PINS Two Pins SERVO BODY 6 x 1 0 mm Five Bolts 6 x 1 0 mm Seven Bolts O RING ATF STRAINER SERVO DETENT BASE ATF FE...

Page 1078: ...pump driven gear shaft 4 Install the torque converter check valve and spring and the cooler check valve and spring on the main valve body then install the two dowel pins and the regulator separator p...

Page 1079: ...TERSHAFT SUBASSEMBLY SECONDARY SHAFT SUBASSEMBLY COUNTERSHAFT 5TH GEAR REVERSE SELECTOR HUB REVERSE SELECTOR COUNTERSHAFT REVERSE GEAR COUNTERSHAFT 2ND GEAR REVERSE IDLER GEAR SHAFT REVERSE IDLER GEAR...

Page 1080: ...r housing then install the countershaft 5th gear and reverse selector hub on the countershaft 4 Turn the shift fork shaft A so the large chamfered hole is facing the fork bolt hole Then install the sh...

Page 1081: ...transmission housing G on the torque converter housing then install the transmission housing mounting bolts along with the harness clamp bracket H and transmission hangers I 11 Tighten the mounting bo...

Page 1082: ...the park gear and the old locknut Threads of the countershaft and the old locknut Old conical spring washer 3 Install the park gear A using the old locknut B and a collar C Hold the park pawl D again...

Page 1083: ...rshaft 3rd gear axial clearance in at least three places while moving the countershaft 3rd gear A Use the average as the actual clearance If the clearance is out of standard select the appropriate 31...

Page 1084: ...que wrench to tighten the locknut Do not use an impact wrench Secondary shaft locknut has left hand threads 15 Remove the old locknuts and old conical spring washers from the mainshaft and secondary s...

Page 1085: ...B 23 Tighten the locknuts to 167 N m 17 0 kgf m 123 lbf ft NOTE Use a torque wrench to tighten the locknuts Do not use an impact wrench Countershaft and secondary shaft locknuts have left hand threads...

Page 1086: ...ing on the input shaft mainshaft speed sensor then install it in the end cover 33 Install the 8 x 12 mm ATF feed pipe A with its filter side into the transmission housing 34 Install the new gasket B i...

Page 1087: ...the new O ring D Install the ATF passage body E on the transmission housing if it was removed 40 Install the new ATF filter A on the transmission housing 41 Install the filter line bracket B on the A...

Page 1088: ...switch clicks in the N position 50 Set the control shaft A to the N position by turning it NOTE Be careful not to squeeze the end of the control shaft tips together when turning into position If the t...

Page 1089: ...3rd clutch pressure switch connector A and A T wire harness ground terminal B on the connector bracket C then install the clips D on the bracket E 54 Install the switch cover F 55 Install the ATF temp...

Page 1090: ...ER CARRIER BEARING BEARING OUTER RACE THRUST WASHER C B A A 1 Install both axles and place the differential assembly on V blocks A 2 Check the backlash of the pinion gears B with a dial indicator C 3...

Page 1091: ...sscross pattern Attachment 40 x 50 mm 07LAD PW50601 NOTE The bearing and outer race should be replaced as a set Inspect and adjust the bearing preload whenever bearing is replaced Check the bearing fo...

Page 1092: ...07GAD PG40101 or 07GAD PG40100 Oil seal driver attachment 07JAD PH80101 1 Remove the differential assembly 2 Remove the oil seal A from the transmission housing B 3 Remove the oil seal A from the tor...

Page 1093: ...bearing and outer race Coat all parts with ATF during installation 1 Remove the bearing outer race from the transmission housing by heating the housing to about 212 F 100 C with a heat gun Do not heat...

Page 1094: ...ting the housing to about 212 F 100 C with a heat gun E Do not heat the housing to more than of 212 F 100 C NOTE Let the transmission housing cool to room temperature before adjusting the bearing prel...

Page 1095: ...wel pins C on the torque converter housing D Align the spring pin on the control shaft E with the transmission housing groove 8 Install the transmission housing F with the transmission hangers G and h...

Page 1096: ...91 in FF 41443 PGH 000 2 325 mm 0 092 in G 41444 P7T 000 2 35 mm 0 093 in GG 41444 PGH 000 2 375 mm 0 094 in H 41445 P7T 000 2 40 mm 0 094 in HH 41445 PGH 000 2 425 mm 0 095 in I 41446 P7T 000 2 45 mm...

Page 1097: ......

Page 1098: ...ft Removal 16 3 Driveshaft Disassembly 16 5 Driveshaft Reassembly 16 9 Driveshaft Installation 16 16 Intermediate Shaft Removal 16 17 Intermediate Shaft Disassembly 16 18 Intermediate Shaft Reassembly...

Page 1099: ...Seal Driver Attachment 1 07LAF SM40300 Support Base Attachment 1 07MAC SL00100 Ball Joint Remover 32 mm 1 07XAC 001020A Threaded Adapter 24 x 1 5 mm 1 07746 0010300 Attachment 42 x 47 mm 1 07749 0010...

Page 1100: ...oint remover 32 mm 07MAC SL00100 Ball joint thread protector 07AAF SDAA100 1 Loosen the wheel nuts slightly 2 Raise the front of the vehicle and support it with safety stands in the proper locations 3...

Page 1101: ...when installing the remover 8 Separate the ball joint from the lower arm C with the special tool see page 18 10 9 Pull the knuckle outward and remove the driveshaft outboard joint from the front whee...

Page 1102: ...mage the boot If the boot band is a locking tab type A pry up the locking tabs B with a screwdriver and lift up the end of the band If the boot band is a double loop type C lift up 3 Make a mark A on...

Page 1103: ...eshaft E to identify the position of the spider on the shaft NOTE The spider C is left driveshaft spider D is right driveshaft 6 Remove the spider 7 Wrap the splines on the driveshaft with vinyl tape...

Page 1104: ...partially to the inboard joint side Be careful not to damage the boot 3 Wipe off the grease to expose the driveshaft and the outboard joint inner race 4 Make a mark A on the driveshaft B at the same p...

Page 1105: ...7 Remove the driveshaft from the vise 8 Remove the circlip from the driveshaft 9 Wrap the splines on the driveshaft with vinyl tape A to prevent damage to the boot 10 Remove the outboard boot Be care...

Page 1106: ...NT Left driveshaft SET RING SNAP RING SPIDER INBOARD BOOT CIRCLIP DRIVESHAFT EAR CLAMP BAND OUTBOARD JOINT OUTBOARD BOOT cont d Replace Replacement parts only Replace Replace Use the grease included i...

Page 1107: ...as needed during this procedure 1 Wrap the splines with vinyl tape A to prevent damage to the inboard boot 2 Install the inboard boot to the driveshaft then remove the vinyl tape Be careful not to da...

Page 1108: ...haft so the inboard joint points up to prevent it from falling off 7 Adjust the length of the driveshafts to the figure as shown then adjust the boots to halfway between full compression and full exte...

Page 1109: ...ft up the boot band tool to bend the free end of the band 90 degrees to the clip Center punch the clip then fold over the remaining tail onto the clip 14 Unwind the boot band tool and cut off the exce...

Page 1110: ...ing 1 Wrap the splines with vinyl tape A to prevent damage to the outboard boot 2 Install the new ear clamp bands B and outboard boot then remove the vinyl tape Be careful not to damage the boot 3 Ins...

Page 1111: ...e from 10 cm 4 in Do not use a hammer as excessive force may damage the driveshaft Be careful not to damage the threaded section A of the outboard joint 6 Check the alignment of the paint mark A with...

Page 1112: ...he ear portion A of the band with a commercially available boot band pincers Kent Moore J 35910 or equivalent B 10 Check the clearance between the closed ear portion of the band If the clearance is no...

Page 1113: ...shaft intermediate shaft 3 Clean the areas where the driveshaft contacts the differential thoroughly with solvent or brake cleaner and dry with compressed air Insert the inboard end A of the driveshaf...

Page 1114: ...veshaft and surrounding parts 11 Tighten the flange bolts and the self locking nut with the vehicle s weight on the damper 12 Refill the transmission with recommended fluid 4 speed 1999 2001 automatic...

Page 1115: ...mm 07746 0010300 1 Remove the heat shield A and intermediate shaft outer seal B from the bearing support C 2 Remove the set ring D and the external snap ring E 3 Press the intermediate shaft A out of...

Page 1116: ...FLANGE BOLTS 6 x 1 0 mm 10 N m 1 0 kgf m 7 2 lbf ft HEAT SHIELD INTERMEDIATE SHAFT BEARING EXTERNAL SNAP RING OUTER SEAL INTERMEDIATE SHAFT BEARING SUPPORT RING INTERNAL SNAP RING BEARING SUPPORT SET...

Page 1117: ...to the Exploded View as needed during this procedure 1 Clean the disassembled parts with solvent and dry them with compressed air Do not wash the rubber parts with solvent 2 Press the intermediate sha...

Page 1118: ...intermediate shaft A contacts the transmission differential thoroughly with solvent or brake cleaner and dry with compressed air Insert the intermediate shaft assembly into the differential Hold the...

Page 1119: ......

Page 1120: ...and Adjustment 17 12 Fluid Replacement 17 14 Power Steering Hose Line and Pressure Switch Replacement 17 15 Pump Replacement 17 16 Pump Overhaul 17 17 Steering Wheel Removal 17 22 Steering Wheel Disas...

Page 1121: ...linder End Seal Remover Attachment 1 07RAK S040122 P S Joint Adaptor Hose 1 07VAK P8A011A P S Joint Adaptor Pump 1 07VAK P8A012B P S Joint Adaptor Plate Pump 1 07XAA 001030A Engine Support Fixture 1 0...

Page 1122: ...Adjustment page 17 12 Replacement page 17 16 Overhaul page 17 17 Replacement page 23 376 Rack Guide Adjustment page 17 29 Steering Gearbox Removal page 17 30 Steering Gearbox Overhaul page 17 34 Steer...

Page 1123: ...even or rough steering 1 2 3 4 5 6 Check the rack guide adjustment see page 17 29 Check power steering pump belt adjustment see page 17 12 Check for low or erratic engine idle speed see page 11 201 Ch...

Page 1124: ...nd seal on the gearbox side Fluid leaks from the right tie rod boot Replace the cylinder end seal Fluid leaks from pinion shaft near the lower steering joint bolt Replace the valve body unit Fluid lea...

Page 1125: ...Replace the gearbox 6 Adjust the rack guide see page 17 29 and retest Repair is completed Replace the gearbox 7 Check for feed and return lines between the pump and the gearbox for clogging and deform...

Page 1126: ...e page 17 8 NOTE This test should be done with original equipment tires and wheels at the correct tire pressure 1 Check the power steering fluid level see page 17 14 and pump belt tension see page 17...

Page 1127: ...NUT STEERING JOINTS GEARBOX MOUNTING CUSHIONS Inspect for damage and deterioration Inspect for damage and deterioration Inspect for loose mounting hardware Inspect loose mounting bolts Inspect for dam...

Page 1128: ...et hose A to the P S joint adapter hose 4 Install the P S pressure gauge to the P S joint adapter pump 5 Fully open the shut off valve A 6 Fully open the pressure control valve B 7 Start the engine an...

Page 1129: ...e to the P S pressure gauge then connect the pump outlet hose A to the P S joint adapter hose 4 Install the P S pressure gauge to the P S joint adapter pump 5 Open the pressure control valve A fully 6...

Page 1130: ...models Check for leaks at the pump seal inlet and outlet fittings Check for leaks at the mating surface and flare nut connections Inspect hoses for damage leaks interference and twisting Inspect flui...

Page 1131: ...uge face toward the engine and measure the tension of the belt Follow the manufacture s instructions If the belt is worn or damaged replace it NOTE Remove the belt tension gauge carefully to avoid hit...

Page 1132: ...e power steering pump pulley A and the crankshaft pulley B 2 If you installed a new belt run the engine for 5 minutes then readjust the belt to the used belt specifications 3 Loosen the power steering...

Page 1133: ...off any spilled fluid at once 2 Connect a hose B of suitable diameter to the disconnected return hose and put the hose end in a suitable container 3 Start the engine let it run at idle and turn the st...

Page 1134: ...f m 8 7 lbf ft RETURN LINE 16 x 1 5 mm 28 N m 2 9 kgf m 21 lbf ft FEED HOSE 14 x 1 5 mm 37 N m 3 8 kgf m 27 lbf ft 00 04 models A B A A Note these items during installation Connect each hose to the co...

Page 1135: ...loosening the pump adjusting nut E then remove pump mounting wheel with pump removed 5 Connect the pump outlet hose and inlet hose to the 6 the mounting bolts and nut 7 Install the pump belt A on the...

Page 1136: ...t 16 7 x 1 8 mm O RING FLOW CONTROL VALVE SPRING FLANGE BOLTS 11 N m 1 1 kgf m 8 0 lbf ft INLET JOINT 13 x 1 9 mm O RING 51 x 2 4 mm O RING 5 mm ROLL PIN PUMP COVER FLANGE BOLTS 20 N m 2 0 kgf m 14 lb...

Page 1137: ...the pump cover and pump cover seal 6 Remove the outer side plate pump cam ring pump rotor pump vanes side plate and O rings 7 Remove the snap ring then remove the subvalve from the pump housing 8 Remo...

Page 1138: ...roughness remove the faulty ball bearing A and install a new one B 15 Inspect each part shown with an asterisk in the Exploded View if any of them are worn or damaged replace the pump as an assembly 1...

Page 1139: ...er the two roll pins with its mark B facing down 24 Assemble pump rotor A to the pump cover B 25 Set the 10 vanes C in the grooves in the rotor Make sure that the round ends D of the vanes are in cont...

Page 1140: ...it on the flow control valve cap D then install the cap on the pump housing and tighten it 32 Coat the new 13 mm O ring A with power steering fluid and install it on the inlet joint B Install the inle...

Page 1141: ...ise control switch connector B 3 Remove the steering wheel nut 99 01 models or bolt 02 04 models Install a steering wheel puller A on the steering wheel B Free the steering wheel from the steering col...

Page 1142: ...17 23 Steering Wheel Disassembly Reassembly STEERING WHEEL RADIO REMOTE SWITCH STEERING WHEEL REAR COVER COVER ACCESS PANEL COVER CRUISE CONTROL SET RESUME SWITCH HOOK PLATE 5 mm SCREWS 4 mm SCREWS...

Page 1143: ...p on the steering wheel or steering column shaft when installing the steering wheel 3 For 99 01 models install a new steering wheel nut and tighten it to 49 N m 5 0 kgf m 36 lbf ft 4 For 02 04 models...

Page 1144: ...attery 2 Remove the driver s airbag steering wheel and cable reel see page 23 368 3 Set the column shaft A in the neutral position by pulling up the steering column to uppermost position then lower it...

Page 1145: ...groove in the pinion shaft 4 Pull on the steering joint to make sure that the steering joint is fully seated Then install the upper joint bolt and tighten it 5 Tighten both the upper and lower joint b...

Page 1146: ...lay replace the steering column as an assembly Check the retaining collar C for damage If it is damaged replace the steering column as an assembly Check the absorbing plates D absorbing plate guides E...

Page 1147: ...top or tightening the 6 mm lock bolt Adjust the preload by turning the tilt lock bolt D left or right Pull up the tilt lever to the uppermost position and install the stop Check the preload again If t...

Page 1148: ...uide screw threaded section and apply new sealant around the first three threads A Loosely install the rack guide screw on the steering gearbox 4 Tighten the rack guide screw to 25 N m 2 5 kgf m 18 lb...

Page 1149: ...t subframe 30 mm 1 18 in from the body and remove install the steering gearbox through the gap produced by lowering the front subframe 1 Drain the power steering fluid see step 1 on page 17 14 2 Recor...

Page 1150: ...B 14 Loosen the adjustable hose clamp C and disconnect the return hose D 15 Lift and support the engine with the special tools Position the tool over the hood latch Loop the cable A around the thrott...

Page 1151: ...nter of the front subframe B Attach a jack to the center of the wood block and support the front subframe securely by raising the jack 19 Loosen the four 14 mm special bolts C on the front subframe so...

Page 1152: ...at were loosened in step 19 23 Remove the clamp for the feed line A from the right mounting bracket B of the steering gearbox 24 Remove the two 10 mm mounting bolts from the left gearbox 25 Move the s...

Page 1153: ...TS 18 N m 1 8 kgf m 13 lbf ft VALVE BODY UNIT GASKET LOCKNUT RACK GUIDE SCREW SPRING RACK GUIDE END PLUG 59 N m 6 0 kgf m 43 lbf ft NUT 25 N m 2 5 kgf m 18 lbf ft GEARBOX HOUSING FLARE NUTS 13 N m 1 3...

Page 1154: ...nt commercially available NOTE Refer to the Exploded View as needed during the following procedure 1 Remove the steering gearbox see page 17 30 2 Remove the boot band A and tie rod clips B Pull the bo...

Page 1155: ...the gearbox housing then remove the nut B from the pinion shaft end 10 Remove the two flange bolts the valve body unit C and gasket D from the gearbox Check that the valve turns smoothly by turning t...

Page 1156: ...gh the rack guide hole of the gearbox housing then position the washer on the cylinder end seal B Make sure that the washer is securely positioned on the cylinder end seal edges 17 Install the socket...

Page 1157: ...d seal Use a press to remove the cylinder end seal Do not try to remove the seal by striking the tool striking the tool would break the cylinder end seal and the seal would remain in the gearbox 22 Co...

Page 1158: ...piston When installing the cylinder end seal be careful not damage the lip of the seal with the edges or teeth of the steering rack 29 Remove the vinyl tape from the steering rack then remove any adh...

Page 1159: ...d then press it into the rack bushing B using the special tools NOTE The open end of the seal should be facing down 36 Coat the new O ring C with power steering fluid and carefully fit it in the groov...

Page 1160: ...ified torque After tightening use a drift to stake the plug shoulder E against the grearbox housing 44 Tighten the flange bolts to the specified torque 45 Before installing the cylinder lines coat the...

Page 1161: ...the right side steering rack with a wrench and tighten the both rack ends with another wrench Be careful not to damage the rack surface with the wrench 51 Bend the lock washer A back against the flat...

Page 1162: ...the tabs A with the holes B of the band 56 Close the ear portion A of the band with a commercially available pincers Oetiker 1098 or equivalent B 57 Slide the rack right and left to be certain that th...

Page 1163: ...ront subframe and body from the driver s side Place the gearbox in position on the subframe 3 Loosely install the two 10 mm gearbox mounting bolts A 4 Install the mounting cushion A on the right side...

Page 1164: ...5 kgf m 75 9 lbf ft 7 Carefully raise the front subframe with the jack 8 Install the front stiffener plates A 9 Install the rear stiffener plates A and tighten the mounting bolts to the specified tor...

Page 1165: ...A B 12 Install the rear engine mount A 13 Remove the engine support fixture 14 Connect the return hose A securely and tighten the adjustable hose clamp B 15 Connect the feed line C and tighten the 14...

Page 1166: ...ft line up the bolt hole D with the flat portion E on the shaft Slip the lower end of the steering joint onto the pinion shaft line up the bolt hole F with the groove around the shaft and loosely inst...

Page 1167: ...ocedure see page 11 202 Do the power window control unit reset procedure see page 22 200 Set the clock Enter the anti theft codes for the radio and the navigation system the custmer s radio station pr...

Page 1168: ...0 Knuckle Hub Replacement 18 11 Ball Joint Boot Replacement 18 16 Lower Arm Removal Installation 18 17 Damper Spring Replacement 18 18 Hub Bearing Replacement 18 22 Upper Arm Removal Installation 18 2...

Page 1169: ...Thread Protector 12 mm 1 07GAF SE00100 Hub Dis Assembly Tool 1 07MAC SL00200 Ball Joint Remover 28 mm 1 07746 0010500 Attachment 62 x 68 mm 1 07749 0010000 Driver 1 07948 SB00101 Attachment 96 mm 1 07...

Page 1170: ...onent Location Index FRONT DAMPER LOWER ARM HUB KNUCKLE Removal page 18 19 Disassembly Inspection page 18 19 Reassembly page 18 20 Installation page 18 20 Removal Installation page 18 17 Replacement p...

Page 1171: ...30 Inspection page 18 30 Installation page 18 31 Replacement page 18 22 Removal Installation page 18 29 Removal Installation page 18 27 Removal page 18 28 Installation page 18 28 Removal Installation...

Page 1172: ...move it up and down and right and left to check for wobbling Use commercially available computerized four wheel alignment equipment to measure wheel alignment caster camber toe and turning angle Follo...

Page 1173: ...e front wheels Lower the front of the vehicle to the ground and bounce the front of the vehicle several times to stabilize the suspension 6 Measure the camber angle If the measurement is within specif...

Page 1174: ...e same direction until the front wheels are pointing straight ahead 5 Turn both tie rods equally until the toe reading on the turning radius gauge is correct 6 After adjusting tighten the tie rod lock...

Page 1175: ...t and left while applying the brake and measure the turning angle of both wheels 2 If the turning angle is not within the specifications check for bent or damaged suspension components 1 Raise the veh...

Page 1176: ...0 0 7 mm 0 0 03 in Service Limit 1 5 mm 0 06 in 18 9 Wheel Runout Inspection 1 Raise the vehicle and support it with safety stands in the proper locations see page 1 15 2 Check for bent or deformed wh...

Page 1177: ...t boot Adjust the jaw spacing by turning the pressure bolt 4 Once the special tool is in place turn the adjusting bolt A as necessary to make the jaws parallel Then hand tighten the pressure bolt B an...

Page 1178: ...7 2 lbf ft FRONT HUB BRAKE DISC WHEEL NUT 12 x 1 5 mm 108 N m 11 0 kgf m 79 6 lbf ft SPINDLE NUT 24 x 1 5 mm 245 N m 25 0 kgf m 181 lbf ft SPLASH GUARD KNUCKLE CENTER CAP FLANGE NUT 16 x 1 5 mm 157 N...

Page 1179: ...pport it with safety stands in the proper locations see page 1 15 2 Remove the wheel nuts A and front wheel B 3 Raise the locking tab on the spindle nut C then remove the nut 4 Remove the brake hose m...

Page 1180: ...al tool see page 18 10 13 Remove the lock pin A from the lower arm ball joint castle nut B and remove the nut 14 Remove the lower ball joint from the knuckle using the special tool see page 18 10 15 R...

Page 1181: ...ng inner race A from the hub B using the special tool a commercially available bearing separator C and a press 21 Wash the knuckle and hub thoroughly in high flash point solvent before reassembly 22 P...

Page 1182: ...em only far enough to align the slot with the ball joint pin hole Do not align the castle nut by loosening it Install new lock pins on the castle nuts after torquing Raise the locking tab on the spind...

Page 1183: ...the base Do not let dirt or other foreign materials get into the boot 4 Install the boot onto the ball joint then squeeze it gently to force out any air 5 For a lower ball joint adjust the special too...

Page 1184: ...ove the lower arm mounting bolt C 3 Remove the lower arm from the rear beam 5 Install the lower arm in the reverse order of removal and note these items Be careful not to damage the ball joint boot wh...

Page 1185: ...CUSHION DUST COVER PLATE DUST COVER BUMP STOP DAMPER SPRING DAMPER UNIT DAMPER MOUNTING BEARING DAMPER MOUNTING WASHER DAMPER MOUNTING BASE SPRING UPPER SEAT Replace Check for deterioration and damag...

Page 1186: ...the three flange nuts NOTE Damper springs are different left and right Mark the springs L and R before you continue 1 Compress the damper spring with a commercially available strut spring compressor...

Page 1187: ...washer and self locking nut Align the bottom of the damper spring and the spring lower seat B 3 Compress the damper spring 4 Install the damper mounting washer A and a new 12 mm self locking nut B 5 H...

Page 1188: ...ff the safety stands 4 Tighten the damper pinch bolts and flange nuts 5 Tighten the flange nuts on top of the damper to the specified torque value 6 Install the service caps 7 Install the front wheel...

Page 1189: ...N m 3 5 kgf m 25 lbf ft CENTER CAP BRAKE DRUM BRAKE SHOE BACKING PLATE KNUCKLE HUB includes bearing SPINDLE NUT 24 x 1 5 mm 245 N m 25 0 kgf m 181 lbf ft HUB CAP BRAKE DISC DRUM 12 x 1 25 mm 93 N m 9...

Page 1190: ...om the hub bearing unit Turn each bolt two turns at a time to prevent cocking the brake drum excessively Remove the brake drum from the hub bearing unit If the drum does not come off easily back off t...

Page 1191: ...and rear wheel B 4 Remove the caliper mounting bolts and hang the caliper assembly A to one side To prevent damage to the caliper assembly or brake hose use a short piece of wire to hang the caliper...

Page 1192: ...ticular attention to the following items Wash the bearing and spindle thoroughly in high flash point solvent before reassembly Before installing the new spindle nut apply a small amount of engine oil...

Page 1193: ...e vehicle 6 Install the upper arm 7 Install the upper arm bolt and castle nut Tighten finger tight 8 Position a floor jack at the connecting point of the lower arm B and the knuckle A 9 Raise the rear...

Page 1194: ...arm A from the vehicle 5 Install the lower arm A 6 7 Position a floor jack at the connecting point of lower arm B and the knuckle A Raise the rear suspension with the floor jack until the vehicle just...

Page 1195: ...jack gradually 6 Remove the spring A upper spring seat B and lower spring seat C 7 Remove the self locking nut D and flange bolt E 1 Lower the rear suspension position the lower arm B and loosely ins...

Page 1196: ...5 Position a floor jack at the connecting point of the lower arm and the knuckle 6 Remove the flange bolts A and B from the trailing arm 7 Install the trailing arm in the reverse order of removal and...

Page 1197: ...nsion begins to compress 3 Remove the flange bolt B from the body 4 Remove the self locking nut C from the knuckle 5 Compress the damper D by hand and remove it from the vehicle 1 Push on the damper a...

Page 1198: ...t into position Loosely install the flange bolt B and self locking nut C 2 Raise the rear suspension with a floor jack until the vehicle just lifts off the safety stands 3 Tighten the flange bolt and...

Page 1199: ...op Replacement SPRING BUMP STOP 10 x 1 25 mm 39 N m 4 0 kgf m 29 lbf ft SPRING UPPER SEAT SPRING LOWER SEAT Check for weakened compression and damage Check for weakness and damage Check for deteriorat...

Page 1200: ...m B and the knuckle 3 Remove the wheel sensor A from the lower arm B Do not disconnect the wheel sensor connector 4 Remove the flange bolt C that connects the lower arm B and the knuckle 5 Lower the f...

Page 1201: ...er the rear suspension Position the lower arm B and loosely install the flange bolt A and self locking nut C 4 Position a floor jack at the connecting point of the lower arm B and the knuckle 5 Slowly...

Page 1202: ...st 19 11 Front Brake Pad Inspection and Replacement 19 12 Front Brake Disc Inspection 19 14 Front Brake Caliper Overhaul 19 15 Master Cylinder Replacement 19 16 Master Cylinder Inspection 19 16 Brake...

Page 1203: ...g Brake Cable Replacement page 19 37 Rear Drum Brake Inspection page 19 19 Rear Brake Shoe Replacement page 19 21 Rear Wheel Cylinder Replacement page 19 24 Brake Pedal Height Check and Brake Pedal Po...

Page 1204: ...Replacement page 19 25 Rear Brake Disc Inspection page 19 27 Rear Brake Caliper Overhaul page 19 28 Brake Pedal Height Check and Brake Pedal Position Switch Adjustment page 19 6 Brake Hose and Line I...

Page 1205: ...damage or signs of fluid leakage at Line joints Modulator 1 Start the engine and let it warm up to operating temperature 2 Attach a 50 mm 2 in piece of masking tape along the bottom of the steering w...

Page 1206: ...booster 4 Without removing the brake lines unbolt and separate the master cylinder from the booster then spin the wheels to check for brake drag Go to step 5 Check the brake pedal position switch adj...

Page 1207: ...utout C Measure the pedal height D from the middle of the left side of the pedal pad E 3 With the engine off inspect the pedal free play A on the pedal pad B by pushing the brake pedal by hand 4 If th...

Page 1208: ...number of clicks B If the number of pedal clicks is excessive adjust the parking brake 2 Check the rear brake shoe self adjuster and make sure the brake shoes are properly adjusted 1 Raise the rear of...

Page 1209: ...turned 3 Back off the adjusting nut in half turn increments and check for proper adjustment 4 6 clicks at a pedal force of 294 N 30 kgf 66 lbf 1 Raise the rear of the vehicle and support it with safet...

Page 1210: ...es contact the paint wash it off immediately with water The reservoir on the master cylinder must be at the MAX upper level mark at the start of the bleeding procedure and checked after bleeding each...

Page 1211: ...ITION SWITCH UNDER HOOD FUSE RELAY BOX GAUGE ASSEMBLY IG1 MAIN 50A G301 Canada USA BATTERY BATTERY 120A ABS TCS CONTROL UNIT DRL INDICATOR LIGHT Canada DAYTIME RUNNING LIGHTS CONTROL UNIT YEL YEL YEL...

Page 1212: ...or come on at the same time check the ABS see page 19 41 or TCS see page 19 81 first If the parking brake switch fluid level switch is OK but the brake system indicator does not function check the ABS...

Page 1213: ...locations see page 1 15 Remove the front wheels 2 Remove the brake hose mounting bolt A from the knuckle 3 Hold the caliper pin with a wrench being careful not to damage the pin boot Remove the calipe...

Page 1214: ...the pads Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down NOTE Check the brake fluid level the brake fluid may overflow the reservoir if too full 14...

Page 1215: ...produced by Kwik way Manufacturing Co and the Front Brake Disc Lathe offered by Snap on Tools Co are approved for this operation NOTE If the brake disc is beyond the service limit for A new disc shoul...

Page 1216: ...e fluid gets on the paint wash it off immediately with water To prevent dripping brake fluid cover disconnected hose joints with rags or shop towels Clean all parts in brake fluid and air dry blow out...

Page 1217: ...ines D from the master cylinder To prevent spills cover the hose joints with rags or shop towels 4 Remove the master cylinder mounting nuts E 5 Remove the master cylinder F from the brake booster G Be...

Page 1218: ...n stop the engine If the pedal height does not vary while pressed for 30 seconds the vacuum booster is OK If the pedal rises the booster is faulty 2 Turn the engine off and wait 30 seconds Press the b...

Page 1219: ...throttle linkage 4 Disconnect the vacuum hose E from the brake booster F 5 Remove the lock pin A and joint pin B 6 Remove the 4 brake booster mounting nuts C 7 Pull the brake booster A forward and rem...

Page 1220: ...e or brush to clean brake assemblies Use an OSHA approved vacuum cleaner NOTE Contaminated brake linings or drums reduce stopping ability Block the front wheels before raising the rear of the vehicle...

Page 1221: ...ntamination 5 Measure the brake lining thickness C Measurement does not include brake shoe thickness 6 If the brake lining thickness is less than the service limit replace the brake shoes as a set 7 C...

Page 1222: ...iston cup leak To avoid this mistake always inspect the wheel cylinder for leakage before removing the brake shoes 1 Raise the rear of the vehicle and support it with safety stands in the proper locat...

Page 1223: ...r return spring C adjuster bolt D self adjuster spring E and lever F and separate the brake shoes 10 Disconnect the parking brake cable from the parking brake lever G and remove the brake shoes 11 Rem...

Page 1224: ...coat the threads with grease Install the adjuster nut thermo clip C and connecting rod D on the adjuster bolt To shorten the adjuster bolt turn the adjuster nut 18 Install the self adjuster lever E o...

Page 1225: ...been removed bleed the brake system see page 19 9 29 Press the brake pedal several times to set the self adjusting brake 30 Adjust the parking brake see page 19 7 Do not spill brake fluid on the vehi...

Page 1226: ...1 15 Remove the rear wheels 2 Check the thickness of the inner pad A and outer pad B Do not include the thickness of the backing plate 3 If the brake pad thickness is less than the service limit repla...

Page 1227: ...de If you are reusing the brake pads always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency 10 Push in the piston A so the caliper will fit over...

Page 1228: ...rake disc as shown and measure the runout at 10 mm 0 4 in from the outer edge of the brake disc 6 If the brake disc is beyond the service limit refinish the brake disc NOTE If the brake disc is beyond...

Page 1229: ...f immediately with water To prevent dripping brake fluid cover disconnected hose joints with rags or shop towels Clean all parts in brake fluid and air dry blow out all passages with compressed air Be...

Page 1230: ...to your health Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies Use an OSHA approved vacuum cleaner 1 Raise the rear of the vehicle and support it with safety st...

Page 1231: ...contamination 4 Measure the parking brake lining thickness B Measurement does not include brake shoe thickness 5 If the brake lining thickness is less than the service limit replace all the parking br...

Page 1232: ...nd support it with safety stands in the proper locations see page 1 15 Remove the rear wheels 2 Release the parking brake and remove the rear 3 Disconnect and remove the upper return springs A 4 Remov...

Page 1233: ...king brake lever C from the brake shoe 1 Apply Molykote 44 MA grease to the sliding surface of the pivot pin A of the rearward brake shoe B 2 Install the parking brake lever C and wave washer D on the...

Page 1234: ...iner C of the rearward brake shoe D Make sure the tension pin does not contact the parking brake lever 6 Clean the threaded portions of the clevis A and coat the threads with multipurpose grease Clean...

Page 1235: ...surface break in when replacing shoes with new linings and or new rear brake disc drum Perform this operation in a safe area 1 Park the vehicle on a firm level surface 2 Do the major parking brake ad...

Page 1236: ...11 lbf ft REAR DRUM BRAKE 99 01 models BLEED SCREW 9 8 N m 1 0 kgf m 7 2 lbf ft REAR DISC BRAKE 02 04 models BLEED SCREW 9 0 N m 0 9 kgf m 7 lbf ft MASTER CYLINDER LINE to ABS or ABS TCS MODULATOR UNI...

Page 1237: ...se from the brake line B using a 10 mm flare nut wrench C 3 Remove and discard the brake hose clip A from the brake hose B 4 Remove the banjo bolt C and disconnect the brake hose from the caliper 5 Re...

Page 1238: ...WITCH Sliding surface 22 N m 2 2 kgf m 16 lbf ft 22 N m 2 2 kgf m 16 lbf ft CABLE CLIP PARKING BRAKE PEDAL ASSEMBLY 22 N m 2 2 kgf m 16 lbf ft 22 N m 2 2 kgf m 16 lbf ft PARKING BRAKE PEDAL PARKING BR...

Page 1239: ...emove the brake shoe assembly see page 19 21 3 Remove the parking brake cable mounting bolts 4 Remove the parking brake cable A from the backing plate B using a 12 mm offset wrench C 5 Install the par...

Page 1240: ...oubleshooting Information 19 41 DTC Troubleshooting Index 19 45 Symptom Troubleshooting Index 19 46 System Description 19 47 Circuit Diagram 19 56 DTC Troubleshooting 19 58 ABS Indicator Circuit Troub...

Page 1241: ...HEEL SENSOR DRIVER S UNDER DASH FUSE RELAY BOX DATA LINK CONNECTOR 16P ABS CONTROL UNIT UNDER HOOD ABS RELAY BOX ABS FAIL SAFE RELAY Inspection page 22 88 Inspection page 19 77 Replacement page 19 78...

Page 1242: ...DTC is cleared the CPU resets and the indicator goes off right after the engine is started if the system is OK If the CPU cannot be activated or it fails the ABS indicator comes on but the DTC is not...

Page 1243: ...ed etc 2 When the ABS indicator does not come on during the test drive but troubleshooting is done based on the DTC check for loose connectors poor terminal contact etc before you start troubleshootin...

Page 1244: ...The system will not indicate the DTC unless these conditions are met The brake pedal is not pressed The ignition switch is turned ON II The engine is stopped The SCS circuit is shorted to body ground...

Page 1245: ...s are met The vehicle speed is 6 mph 10 km h or less The SCS circuit is shorted to body ground before the ignition switch is turned ON II The brake pedal is pressed before the ignition switch is turne...

Page 1246: ...er see page 19 60 DTC 23 Right rear pulser see page 19 60 DTC 24 Left rear pulser see page 19 60 DTC 31 Right front inlet solenoid see page 19 61 DTC 32 Right front outlet solenoid see page 19 61 DTC...

Page 1247: ...shooting see page 19 73 ABS indicator does not go off and no DTCs are stored ABS Indicator Circuit Troubleshooting see page 19 73 Brake system indicator does not come on Brake System Indicator Circuit...

Page 1248: ...t Drives left rear outlet solenoid valve 5 ON Disconnect connector A to turn light on Below 0 3 V 6 YEL BLK FR OUT Front right outlet Drives right front outlet solenoid valve 6 7 BLK GND2 Ground 2 Gro...

Page 1249: ...e 6 BRN FLW Front left wheel negative Detects left front wheel sensor signal 6 7 Wheel Turn wheel at 1 turn second AC 0 053 V or above Reference 0 15 Vp p or above 7 GRN BLU FLW Front left wheel posit...

Page 1250: ...eft wheel positive Detects left rear wheel sensor signal 17 18 Wheel Turn wheel at 1 turn second AC 0 053 V or above Reference 0 15 Vp p or above 18 GRY RLW Rear left wheel positive 19 GRN YEL RRW Rea...

Page 1251: ...SENSOR FL WHEEL SENSOR FR NC NO NO RESERVOIR MODULATOR UNIT When the brake pedal is pressed during driving the wheels can lock before the vehicle comes to a stop In such an event the maneuverability...

Page 1252: ...e vehicle speed during deceleration based on the rate of deceleration The ABS control unit calculates the slip rate of each wheel and it transmits the control signal to the modulator unit solenoid val...

Page 1253: ...ail safe mode 11 13 15 17 Wheel sensor open short to body ground short to power A2 12 14 16 18 Wheel sensor electrical noise intermittent interruption A2 A2 and L2 21 24 Pulser A2 and L2 31 38 Solenoi...

Page 1254: ...e ABS control unit stores a DTC in back up memory when it detects a problem If a problem is detected when the ignition switch is turned ON II the ABS control unit will turn the ABS and EBD system off...

Page 1255: ...e reducing The hydraulic circuit is an independent four channel type one channel for each wheel Pressure intensifying mode Inlet valve open outlet valve closed Master cylinder fluid is pumped out to t...

Page 1256: ...or s magnetic coil AC current is generated The AC frequency changes in accordance with the wheel speed The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel spee...

Page 1257: ...K GRN RED YEL WHT YEL BLK YEL GRN MODULATOR UNIT FL IN FL OUT FR IN RL IN FR OUT RL OUT RR IN RR OUT YEL RED WHT BLK 1 2 YEL WHT BLU PUMP MOTOR G302 BLK BATTERY B1 A6 E16 I4 C14 B8 C10 B16 B11 B14 10...

Page 1258: ...TOR 16P VCC DLC B VCC TXD RXD G101 G501 BLK GRN BLU BRN GRN BLK GRN LT BLU GRY GRN YEL BLU YEL BRN LT BLU PARKING BRAKE SWITCH Closed Brake lever pulled YEL WHT BLU WHT GRN RED IG2 FSR PMR To IG2 To V...

Page 1259: ...No 19 RRW 17 Left rear No 17 RLW Repair short to power in the circuit wire between the ABS control unit and the appropriate wheel sensor Go to step 4 4 Check for continuity between the appropriate whe...

Page 1260: ...he ABS control unit and the wheel sensor Replace the wheel sensor NOTE If the ABS indicator comes on because of electrical noise the indicator goes off when you test drive the vehicle at 19 mph 30 km...

Page 1261: ...he DTC see step 1 on page 19 43 2 Test drive the vehicle at 19 mph 30 km h or more Go to step 3 The system is OK at this time 3 Check the appropriate pulser gears for a chipped tooth see table 21 Righ...

Page 1262: ...propriate ABS control unit connector B 12P solenoid circuit terminal and body ground see table 31 FR IN No 11 32 FR OUT No 6 33 FL IN No 9 34 FL OUT No 4 35 RR IN No 8 36 RR OUT No 3 37 RL IN No 10 38...

Page 1263: ...with a jumper wire see table 31 FR IN No 1 32 FR OUT No 5 33 FL IN No 4 34 FL OUT No 8 35 RR IN No 3 36 RR OUT No 7 37 RL IN No 2 38 RL OUT No 6 9 Check for continuity between the appropriate ABS con...

Page 1264: ...at 20 C 68 F OUT 3 5 at 20 C 68 F 31 FR IN No 11 32 FR OUT No 6 33 FL IN No 9 34 FL OUT No 4 35 RR IN No 8 36 RR OUT No 3 37 RL IN No 10 38 RL OUT No 5 Go to step 14 Replace the modulator unit 14 Disc...

Page 1265: ...heck for loose ABS control unit connectors If necessary substitute a known good ABS control unit and recheck 1 Test drive the vehicle and apply the brakes several times to raise the brake temperature...

Page 1266: ...o 5 with a jumper wire for a moment and check the fuse Check for a short to body ground in the motor power source circuit Go to step 3 3 Remove the ABS MOTOR CHECK 7 5A fuse in the passenger s under d...

Page 1267: ...a moment Go to step 13 Go to step 9 9 Disconnect the pump motor connector 10 Connect the pump motor relay connector terminal No 4 to No 5 with a jumper wire 11 Measure the voltage between the pump mo...

Page 1268: ...oblem recurs replace the ABS control unit 1 Check that the pump motor operates with the ignition switch OFF Go to step 12 Go to step 2 2 Remove the ABS MOTOR CHECK 7 5A fuse in the passenger s under d...

Page 1269: ...o 5 together with a jumper wire Go to step 10 Replace the pump motor 10 Disconnect the ABS control unit connector B 12P 11 Check for continuity between terminal No 12 and body ground Repair short to b...

Page 1270: ...GRN BRN BLK BLK and YEL GRN Leave the ABS fail safe relay removed and go to step 4 Replace the ABS fail safe relay 4 Measure the voltage between the ABS fail safe relay connector terminal No 1 and bo...

Page 1271: ...and body ground Repair short to power in the wire between the ABS control unit and the ABS fail safe relay Go to step 13 13 Check for continuity between the ABS control unit connector terminal No 21...

Page 1272: ...body ground If the problem recurs replace the ABS control unit Repair open in the wire between the ABS control unit and the ABS fail safe relay 1 Clear the DTC see step 1 on page 19 43 2 Test drive th...

Page 1273: ...n page 19 43 2 Test drive the vehicle Make sure all four tires are the specified size Intermittent failure the vehicle is OK at this time 1 Clear the DTC see step 1 on page 19 43 2 Test drive the vehi...

Page 1274: ...tute a known good ABS control unit and recheck Go to step 6 6 Check the ABS indicator bulb in the gauge assembly Go to step 7 Replace the ABS indicator bulb 7 Turn the ignition switch OFF 8 Disconnect...

Page 1275: ...Measure the voltage between the ABS control unit connector A 22P terminal No 11 and body ground Go to step 17 Repair open in the wire between the R C MIRROR 7 5A fuse and the ABS control unit 17 Conn...

Page 1276: ...ge assembly Open circuit inside the fuse box 4 Check the brake system indicator bulb in the gauge assembly Repair open in the brake system indicator circuit Replace the brake system indicator bulb 5 S...

Page 1277: ...ends and joints with a shop towel or equivalent material 1 Remove the intake air duct see step 6 on page 5 3 2 Disconnect the modulator unit connector A and the pump motor connector B 3 Disconnect the...

Page 1278: ...er s side under the dash 2 Disconnect the ABS control unit connectors B 3 Install the ABS control unit in the reverse order of removal 1 Inspect the front and rear pulsers for chipped or damaged teeth...

Page 1279: ...r 19 78 ABS Components Wheel Sensor Replacement 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 lbf ft WHEEL SENSOR 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 lbf ft WHEEL SENSOR Install the sensors carefully to avoid twisting...

Page 1280: ...bleshooting Index 19 86 Symptom Troubleshooting Index 19 88 System Description 19 89 Circuit Diagram 19 106 DTC Troubleshooting 19 112 ABS Indicator Circuit Troubleshooting 19 153 TCS Indicator Circui...

Page 1281: ...X DATA LINK CONNECTOR 16P ABS TCS CONTROL UNIT MULTI RELAY BOX ABS FAIL SAFE RELAY MULTI FUSE RELAY BOX TCS RELAY TCS SWITCH Inspection page 22 88 Inspection page 19 160 Replacement page 19 161 Remova...

Page 1282: ...hen the system returns to normal For all other codes the indicator stays on until the ignition switch is turned OFF For ABS DTCs 12 14 16 18 21 22 23 24 51 52 and 53 the ABS indicator goes off when th...

Page 1283: ...c 2 When the ABS or TCS indicator does not come on during the test drive but troubleshooting is done based on the DTC check for loose connectors poor contact of the terminals etc before you start trou...

Page 1284: ...n The system will not indicate the DTC unless these conditions are met The TCS switch is not pushed The brake pedal is not pressed The ignition switch is turned ON II The engine is stopped The SCS cir...

Page 1285: ...conditions are met The vehicle speed at 6 mph 10 km h or less The SCS circuit is shorted to body ground before the ignition switch is turned ON II The brake pedal is pressed before the ignition switch...

Page 1286: ...rompts on the HDS NOTE See the HDS help menu for specific instructions 1 Press the parking brake pedal with the SCS circuit opened Keep the pedal pressed during the entire DTC clearing procedure 2 Pre...

Page 1287: ...nt pulser see page 19 114 DTC 23 Right rear pulser see page 19 114 DTC 24 Left rear pulser see page 19 114 DTC 31 Right front inlet solenoid see page 19 115 DTC 32 Right front outlet solenoid see page...

Page 1288: ...al see page 19 139 DTC 31 Engine retard command PFINH signal see page 19 140 DTC 32 Engine speed NEP signal see page 19 142 DTC 34 Reference voltage VREF signal see page 19 143 DTC 36 Throttle positio...

Page 1289: ...e is OK at this time see page 19 81 TCS indicator does not come on TCS Indicator Circuit Troubleshooting see page 19 155 TCS indicator does not go off and no DTCs are stored TCS Indicator Circuit Trou...

Page 1290: ...off the indicator 4 GND ABS indicator ON 4 6 V OFF Below 0 3 V 6 BRN SCS Service check signal Detects service check connector signal Use for DTC indication 6 GND SCS circuit Shorted Below 0 3 V Opene...

Page 1291: ...cator OFF Battery Voltage ON About 2 V 20 GRN MCK Motor check Detects pump motor drive signal 20 GND Pump motor ON Battery Voltage OFF Below 0 3 V Remove MCK fuse About 10 V 21 LT BLU RLW Rear left wh...

Page 1292: ...ission to P position then start the engine About 4 V 9 RED BLK THLOUT Throttle out Detects throttle position sensor signal 9 GND Throttle valve Fully closed About 0 5 V Fully opened About 4 8 V 10 LT...

Page 1293: ...RL OUT Rear left outlet Drives left rear outlet solenoid valve 5 GND ON Disconnect 16P connector to turn indicator on Below 0 3 V 6 YEL BLK FR OUT Front right outlet Drives right front outlet solenoi...

Page 1294: ...CS NO TCS NC TCS NO NO NO NC PUMP MOTOR PUMP P M P DAMPING CHAMBER MODULATOR UNIT RESERVOIR NC NC WHEEL SENSOR FL WHEEL SENSOR FR NC NO NO RESERVOIR This system consists of the ABS TCS control unit th...

Page 1295: ...e wheel speed then it controls the brake fluid pressure to reach the target slip rate The TCS provides low speed traction When a drive wheel loses traction on a slipperly road surface and starts to sp...

Page 1296: ...REAR SOLENOID LEFT REAR SOLENOID RIGHT FRONT SOLENOID LEFT FRONT SOLENOID ABS TCS CONTROL UNIT The ABS TCS control unit detects the wheel speed based on the wheel sensor signal it received then it ca...

Page 1297: ...d average Calculate deviation Detect wheel speed Detect wheel speed Detect wheel speed Calculate amount of left front wheel control Drive solenoid Drive solenoid RIGHT FRONT SOLENOID LEFT FRONT SOLENO...

Page 1298: ...s to fail safe mode 11 13 15 17 Wheel sensor open short to body ground short to power A0 12 14 16 18 Wheel sensor electrical noise intermittent interruption A0 L0 21 24 Pulser A0 L0 31 38 Solenoid sho...

Page 1299: ...system will be turned off until the problem goes away ON ON OFF Fail safe mode L1 The ABS TCS control unit stores a DTC in back up memory when it detects a problem If a problem is detected when the i...

Page 1300: ...ator goes off Regular diagnosis Done right after the initial diagnosis until the ignition switch is turned OFF When a problem is detected by self diagnosis the ABS TCS control unit shifts to fail safe...

Page 1301: ...ke pad temperature rises excessively the ABS TCS control unit stops the TCS system and turns the TCS indicator on When the brake pad temperature lowers the ABS TCS control unit turns off the TCS indic...

Page 1302: ...ator controls the caliper fluid pressure directly It is a circulating type modulator because the brake fluid circulates through the caliper the reservoir and the master cylinder The hydraulic control...

Page 1303: ...T TCS NO TCS NC TCS NC TCS NO DAMPING CHAMBER IN OUT RESERVOIR M IN OUT RL FR FL RR IN OUT RESERVOIR IN OUT PUMP PUMP DAMPING CHAMBER MOTOR MASTER CYLINDER TCS NO valve open TCS NC valve closed inlet...

Page 1304: ...NC TCS NO DAMPING CHAMBER IN OUT RESERVOIR M IN OUT RL FR FL RR IN RESERVOIR IN OUT PUMP PUMP DAMPING CHAMBER MOTOR MASTER CYLINDER TCS NO valve closed TCS NC valve open inlet valve closed outlet valv...

Page 1305: ...type As the gear pulser teeth rotate past the wheel sensor s magnetic coil AC current is generated The AC frequency changes in accordance with the wheel speed The ABS TCS control unit detects the whee...

Page 1306: ...TCS NO VALVE When the front wheel speed rises sharply above the vehicle speed the TCS NC valve opens the TCS NO valve closes and the pump motor starts to intensify the front caliper fluid pressure Wh...

Page 1307: ...L BLK RED GRN YEL GRN RED WHT YEL WHT RED GRN YEL GRN LT BLU GRY 6 5 TCS SWITCH TCS INDICATOR ABS INDICATOR BRAKE SYSTEM INDICATOR GAUGE ASSEMBLY BRAKE FLUID LEVEL SWITCH Closed Low fluid B11 C14 B8 C...

Page 1308: ...BLU GRY GRN YEL BLU YEL RED BLU YEL BLU RED BLK YEL BLK RED GRN YEL GRN RED WHT YEL WHT RED GRN YEL GRN LT BLU GRY B11 B9 A19 C2 B7 B10 B1 B2 A7 A31 E1 E3 A11 A6 SCS NEP VCC VCC VCC THLOUT VREF FPTDR...

Page 1309: ...EL BLK RED GRN YEL GRN RED WHT YEL WHT RED GRN YEL GRN LT BLU GRY 6 5 TCS SWITCH TCS INDICATOR ABS INDICATOR BRAKE SYSTEM INDICATOR GAUGE ASSEMBLY BRAKE FLUID LEVEL SWITCH Closed Low fluid B11 C14 B8...

Page 1310: ...T BLU GRY GRN YEL BLU YEL RED BLU YEL BLU RED BLK YEL BLK RED GRN YEL GRN RED WHT YEL WHT RED GRN YEL GRN LT BLU GRY B11 B9 E3 C2 B7 B10 B1 B2 D9 D16 D3 D5 D11 A6 SCS NEP VCC VCC VCC THLOUT VREF FPTDR...

Page 1311: ...L BLK RED GRN YEL GRN RED WHT YEL WHT RED GRN YEL GRN LT BLU GRY TCS SWITCH TCS INDICATOR BRAKE SYSTEM INDICATOR GAUGE ASSEMBLY BRAKE FLUID LEVEL SWITCH Closed Low fluid ALTERNATOR GRN RED GRN RED YEL...

Page 1312: ...RRW G303 G303 WHEEL SENSOR LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR RED BLU YEL BLU RED BLK YEL BLK RED GRN YEL GRN RED WHT YEL WHT RED GRN YEL GRN LT BLU GRY SCS NEP VCC VCC VCC THLOUT VREF FPTDR...

Page 1313: ...t rear No 23 RRW 17 Left rear No 21 RLW Repair short to power in the circuit wire between the ABS TCS control unit and the appropriate wheel sensor Go to step 4 4 Check for continuity between the appr...

Page 1314: ...resistance between the and terminals of the wheel sensor Repair open in the or circuit wire or short between the circuit wire and the circuit wire between the ABS TCS control unit and the wheel sensor...

Page 1315: ...No 21 16 No 23 No 11 No 9 No 21 18 No 21 No 11 No 9 No 23 Repair short to wire between the appropriate wheel sensor and the other wheel sensor Clear the DTC and test drive the vehicle If the ABS indic...

Page 1316: ...opriate ABS TCS control unit connector C 12P solenoid circuit terminal and body ground see table 31 FR IN No 11 32 FR OUT No 6 33 FL IN No 9 34 FL OUT No 4 35 RR IN No 8 36 RR OUT No 3 37 RL IN No 10...

Page 1317: ...th a jumper wire see table 31 FR IN No 11 32 FR OUT No 19 33 FL IN No 14 34 FL OUT No 22 35 RR IN No 13 36 RR OUT No 21 37 RL IN No 12 38 RL OUT No 20 9 Check for continuity between the appropriate AB...

Page 1318: ...TCS control unit connector C 12P terminal and body ground see table IN 8 10 at 68 F 20 C OUT 3 5 at 68 F 20 C 31 FR IN No 11 32 FR OUT No 6 33 FL IN No 9 34 FL OUT No 4 35 RR IN No 8 36 RR OUT No 3 3...

Page 1319: ...No 4 35 RR IN No 8 36 RR OUT No 3 37 RL IN No 10 38 RL OUT No 5 Replace the modulator unit Check for loose ABS TCS control unit connectors If necessary substitute a known good ABS TCS control unit an...

Page 1320: ...mp motor relay connector terminal No 4 to No 5 with a jumper wire for a moment and check the fuse Check for a short to body ground in the motor power source circuit Go to step 3 3 Remove the ABS MOTOR...

Page 1321: ...oment Go to step 13 Go to step 9 9 Disconnect the modulator unit connector 10 Connect pump motor relay connector terminal No 4 to No 5 with a jumper wire 11 Measure the voltage between modulator unit...

Page 1322: ...If the problem recurs replace the ABS TCS control unit 1 Check that the pump motor operates with the ignition switch OFF Go to step 12 Go to step 2 2 Remove the ABS MOTOR CHECK 7 5A fuse in the passen...

Page 1323: ...and No 5 together with a jumper wire Go to step 10 Replace the pump motor 10 Disconnect the ABS TCS control unit connector B 16P 11 Check for continuity between terminal No 15 and body ground Repair s...

Page 1324: ...relay and modulator unit Go to step 3 3 Check the ABS fail safe relay in the ABS relay box see page 22 88 The wire colors of the ABS fail safe relay connector are WHT GRN BRN BLK BLK and YEL GRN Leave...

Page 1325: ...ltage between the modulator unit connector terminal No 2 and body ground Repair short to power in the wire between the ABS fail safe relay TCS relay modulator unit and under hood ABS relay box Go to s...

Page 1326: ...connector terminal No 3 and body ground Go to step 15 Check for an open in the wire between the ABS fail safe relay and body ground If the wire is OK check for poor ground at G201 15 Connect the ABS...

Page 1327: ...km h or more Go to step 3 The system is OK at this time 3 Verify the DTC Check the charging system Do the appropriate troubleshooting for the DTC 1 Clear the DTC see step 1 on page 19 83 2 Test drive...

Page 1328: ...ropriate troubleshooting for DTC 28 Go to step 2 2 Turn the ignition switch OFF 3 Disconnect the modulator unit connector and the ABS TCS control unit connector A 26P 4 Check for continuity between th...

Page 1329: ...r 6 Check for continuity between the appropriate ABS TCS control unit connector A 26P solenoid circuit terminal and body ground see table 24 NOR No 16 25 NCR No 15 26 NOL No 3 27 NCL No 2 Replace the...

Page 1330: ...wire between the ABS TCS control unit and the modulator unit 10 Remove the jumper wires from the modulator unit connector 11 Connect the modulator unit connector 12 Remove the TCS relay and connect t...

Page 1331: ...unit connector terminal No 17 and the TCS relay terminal No 2 Replace the modulator unit Repair open in the wire between the modulator unit and the TCS relay 16 Disconnect the modulator unit connecto...

Page 1332: ...TCS control unit and recheck 1 Check the TCS 10A fuse in the passenger s under dash fuse relay box and reinstall the fuse if it is OK Go to step 2 Replace the fuse and recheck 2 Turn the ignition swit...

Page 1333: ...and the modulator unit 8 Remove the jumper wire from the TCS relay connector 9 Measure the voltage between the modulator unit connector terminal No 17 and body ground Repair short to power in the wire...

Page 1334: ...ABS fail safe relay The wire colors of the ABS fail safe relay connector are WHT GRN BRN BLK BLK and YEL GRN 16 Connect the ABS fail safe relay connector terminal No 1 and No 2 with a jumper wire 17...

Page 1335: ...ay and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first 1 Disconnect PCM connector E 12P and the ABS TCS control unit connector B 16P 2 Check for co...

Page 1336: ...loose PCM connectors If necessary substitute a known good PCM and recheck 6 With an analog voltmeter set to the 10 V or similar range measure the voltage between ABS TCS control unit connector B 16P...

Page 1337: ...between the PCM connector A 32P terminal No 19 and body ground Repair short to body ground in the wire between the PCM and the ABS TCS control unit Go to step 3 3 Connect PCM connector A 32P 4 Start t...

Page 1338: ...e between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first 1 Disconnect the PCM connector A 32P and the ABS TCS control unit connector B...

Page 1339: ...f the problem recurs replace the ABS TCS control unit Repair open in the wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first 1...

Page 1340: ...system is OK at this time If the problem recurs replace the ABS TCS control unit Repair open in the wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troublesho...

Page 1341: ...B 16P terminal No 7 and body ground Check for loose ABS TCS control unit connectors If necessary substitute a known good ABS TCS control unit and recheck Repair open in the wire between the PCM and t...

Page 1342: ...oose PCM connectors If necessary substitute a known good PCM and recheck 6 With an analog voltmeter set to the 10 V or similar range measure the voltage between the ABS TCS control unit connector B 16...

Page 1343: ...CM connector E 31P terminal No 3 and body ground Repair short to body ground in the wire between the PCM the gauge assembly and the ABS TCS control unit Go to step 3 3 Connect the PCM connector E 31P...

Page 1344: ...wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first 1 Disconnect the PCM connector D 17P and the ABS TCS control unit connect...

Page 1345: ...If the problem recurs replace the ABS TCS control unit Repair open in the wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first...

Page 1346: ...e system is OK at this time If the problem recurs replace the ABS TCS control unit Repair open in the wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troublesh...

Page 1347: ...B 16P terminal No 7 and body ground Check for loose ABS TCS control unit connectors If necessary substitute a known good ABS TCS control unit and recheck Repair open in the wire between the PCM and t...

Page 1348: ...oose PCM connectors If necessary substitute a known good PCM and recheck 6 With an analog voltmeter set to the 10 V or similar range measure the voltage between the ABS TCS control unit connector B 16...

Page 1349: ...tween the PCM connector A 32P terminal No 19 and body ground Repair short to body ground in the wire between the PCM and the ABS TCS control unit Go to step 3 3 Connect the PCM connector A 32P 4 Start...

Page 1350: ...wire between the PCM and ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first 1 Disconnect the PCM connector E 20P and the ABS TCS control unit connector B...

Page 1351: ...blem recurs replace the ABS TCS control unit Repair open in the wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoot the PGM FI or ABS first 1 Disconne...

Page 1352: ...system is OK at this time If the problem recurs replace the ABS TCS control unit Repair open in the wire between the PCM and the ABS TCS control unit NOTE If the MIL or ABS indicator is ON troubleshoo...

Page 1353: ...milar range measure the voltage between the ABS TCS control unit connector B 16P terminal No 7 and body ground Check for loose ABS TCS control unit connectors If necessary substitute a known good ABS...

Page 1354: ...tute a known good ABS TCS control unit and recheck Go to step 6 6 Check the ABS indicator bulb in the gauge assembly Go to step 7 Replace the ABS indicator bulb 7 Turn the ignition switch OFF 8 Discon...

Page 1355: ...the voltage between the ABS TCS control unit connector A 26P terminal No 13 and body ground Go to step 17 Repair open in the wire between the R C MIRROR 7 5A fuse and the ABS TCS control unit 17 Conn...

Page 1356: ...ator bulb 4 Connect the gauge assembly connector B 22P terminal No 13 and body ground with a jumper wire Go to step 5 Replace the printed circuit board in the gauge assembly 5 Remove the jumper wire a...

Page 1357: ...body ground Go to step 9 Repair open in the wire between the driver s under dash fuse relay box and the ABS TCS control unit 9 Turn the ignition switch OFF 10 Disconnect the ABS TCS control unit conne...

Page 1358: ...assembly Open circuit inside the fuse box 4 Check the brake system indicator bulb in the gauge assembly Repair open in the brake system indicator circuit Replace the brake system indicator bulb 5 Sta...

Page 1359: ...and joints with a shop towel or equivalent material 1 2 Push the modulator unit connector lock A and turn the connector lever B 3 Disconnect the modulator unit connector C 4 Disconnect the brake line...

Page 1360: ...SWITCH CONNECTOR TCS SW BLU ORN IG1 YEL 1 Remove the TCS switch A from the switch panel 2 Check for continuity between terminal No 5 and No 6 There should be continuity when the TCS switch is pushed W...

Page 1361: ...n the driver s side under the dash 2 Disconnect the ABS TCS control unit connectors B 3 Install the ABS TCS control unit in the reverse order of removal 1 Inspect the front and rear pulsers for chippe...

Page 1362: ...Front Rear 19 161 Wheel Sensor Replacement 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 lbf ft WHEEL SENSOR 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 lbf ft WHEEL SENSOR Install the sensors carefully to avoid twisting wires...

Page 1363: ......

Page 1364: ...color coding Related components are located in the steering column front console dashboard dashboard lower panel in the dashboard above the glove box in the front seats and around the floor Do not use...

Page 1365: ...t 20 33 Manual Mirror Replacement 20 34 Mirror Holder Replacement 20 35 Rearview Mirror Replacement 20 36 Component Location Index Windshield Rear Window 20 37 Component Location Index Sliding Door Gl...

Page 1366: ...Seat back Recline Lever Replacement 20 120 Third Row Seat Cushion Latch Lever Replacement 20 121 Third Row Seat Cushion Latch Cable Replacement 20 122 Third Row Seat back Recline Cable Replacement 20...

Page 1367: ...E Passenger s PULL POCKET TRIM POWER WINDOW SWITCH GLASS STOP FRONT DOOR WINDOW OUTER TRIM SPEAKER GRILLE FRONT DOOR REFLECTOR PULL POCKET BRACKET SEAT HEATER SWITCH SUBHARNESS For some 02 04 models S...

Page 1368: ...INNER HANDLE OUTER HANDLE PROTECTOR RETAINER CLIP GLASS POWER DOOR LOCK SWITCH Driver s CENTER LOWER CHANNEL GLASS RUN CHANNEL 01 04 models LOWER RUN CHANNEL 01 04 models IMMOBILIZER LABEL 01 04 mode...

Page 1369: ...de SLIDING DOOR FRONT UPPER TRIM LOWER ROLLER SUB BASE LOWER ROLLER MALE STOPS SLIDING DOOR PANEL FEMALE STOP Body side DOOR HOOK PIN LOWER ROLLER LEVER LOWER ROLLER LEVER CABLE CENTER LOWER SEAL Powe...

Page 1370: ...DOOR LATCH CABLE DOOR LOCK REMOTE CONTROL CHILD PROTECTION LEVER LATCH HOLE COVER DOOR AUTO CLOSE CABLE Manual sliding door DOOR LOCK REMOTE CONTROL POWER DOOR LOCK ACTUATOR For some models LATCH cont...

Page 1371: ...TER RAIL END CAP POWER SLIDING DOOR PULLEY MOUNT POWER SLIDING DOOR MOTOR UNIT FUEL FILL DOOR SWITCH POWER SLIDING DOOR CONTROL UNIT POWER SLIDING DOOR BUZZER Left side only QUARTER PLASTIC COVER CENT...

Page 1372: ...ke care not to scratch the door panel 2 Remove the inner handle A Take care not to scratch the door panel 1 Pry out the cap B and remove the screw 2 Pull the inner handle forward and out half way 3 Di...

Page 1373: ...e door panel in the reverse order of removal and note these items Replace any damaged clips Push the clips into place securely Make sure the connectors are plugged in properly and the inner handle rod...

Page 1374: ...ner clip B then remove the lock cylinder C 5 Remove the screw then separate the lock cylinder A and cylinder switch B 6 Disconnect the cylinder switch connector A and detach the harness clip B and rel...

Page 1375: ...e sure the connector is plugged in properly and each rod is connected securely Make sure the door locks and opens properly When installing the lock cylinder leave the outer door handle bolts loose so...

Page 1376: ...and note these items Make sure the actuator connectors are plugged in properly and each rod is connected securely Make sure the door locks and opens properly When reinstalling the door panel make sur...

Page 1377: ...multipurpose grease to all the sliding surfaces of the regulator A where shown 5 Install the glass and regulator in the reverse order of removal and note these items Roll the glass up and down to see...

Page 1378: ...y available 1 For EX and EX L models Disable the power sliding doors by turning off the main switch 2 Release the clips that hold the front and rear upper trim A B with a commercially available trim p...

Page 1379: ...5 Install the door panel in the reverse order of removal and note these items Replace any damaged clips Push the clips into place securely 6 For EX and EX L models Re home the power sliding doors see...

Page 1380: ...extends from the joint C Put a shop towel D between the door opening E and the outer handle F and use diagonal cutters G to pry the joint out of the arm on the outer handle H Remove the outer handle...

Page 1381: ...to bend any of the cables 3 Install the door lock remote control in the reverse order of removal and note these items Make sure the actuator connector s are plugged in properly and each cable is conne...

Page 1382: ...und its perimeter 4 For EX and EX L models Re home the power sliding doors see page 22 291 1 For EX and EX L models Disable the power sliding doors by turning off the main switch 2 Remove the nuts the...

Page 1383: ...atch C Take care not to bend the cable 2 Install the lower roller latch in the reverse order of removal and note these items Make sure the lower roller latch cable is connected properly Make sure the...

Page 1384: ...hands 1 Place the vehicle on a firm level surface when removing and installing the door 2 Remove these items Taillight see page 22 132 Sliding door see page 20 25 Rear side trim panel see page 20 60...

Page 1385: ...N m 1 0 kgf m 7 2 lbf ft 6 x 1 0 mm 8 N m 0 8 kgf m 6 lbf ft H A I D F I G E B C C B A 8 Remove the bolts securing the front pulley A 9 Remove the nuts securing the rear pulley B 10 Remove the bolts A...

Page 1386: ...til you can see the rear set mark 3 4 After setting the tension turn on the power door master switch and operate the sliding door once with the power sliding door switch 5 Turn off the master power do...

Page 1387: ...nter rail 4 If equipped disconnect the power sliding door motor unit cable from the center roller see step 7 on page 20 19 Take care not to bend the cable 5 If equipped remove the bolts and nuts secur...

Page 1388: ...oor see page 20 2 Plastic cover see page 20 2 3 Carefully lower the glass A until you can see the glass mounting bolts B then loosen them 4 Push the glass A against the center channel C then tighten t...

Page 1389: ...y to equalize the gaps and in or out until it s flush with the body 3 If necessary replace the hinge mounting bolt E with the adjusting bolt P N 90101 SZ3 000 made specifically for door adjustment the...

Page 1390: ...striker too hard 4 Loosen the screws and remove the shop towel 5 Lightly tighten the screws 6 Hold the outer handle out and push the door against the body to be sure the striker allows a flush fit If...

Page 1391: ...Locations Bolt 2 A C D B 5 Remove the bolts securing the center roller A while holding the sliding door 6 Move the door A slightly until the lower roller subbase B lines up with the notch C in the lo...

Page 1392: ...order of removal and note these items Clean the groove portion of each rail and apply multipurpose grease to the lower roller A moving portion of the lower roller plate B and stop spring C If equippe...

Page 1393: ...k the position of the center roller A with a permanent marker This will help you gauge the amount of adjustment needed for the roller 4 Close the sliding door fully then inspect the gaps at the front...

Page 1394: ...ackward and up or down while keeping the center roller level When you re finished with this adjustment torque the center roller bolts 7 Inspect the rear of the door for in or out overhang from the rea...

Page 1395: ...flush go to step 12 If the sliding door is not flush go to step 11 11 Loosen the upper roller bolts then add or remove shims under the upper roller to make the sliding door flush with the body and the...

Page 1396: ...rear edge of the door opening 16 Turn on the power sliding door main switch 17 Hold a piece of paper over the door cushion then close the door with the paper trapped between the cushion and the door...

Page 1397: ...WER MIRROR MANUAL MIRROR REARVIEW MIRROR MIRROR HOLDER MIRROR HOLDER POWER MIRROR ACTUATOR ACCESS LID MIRROR BASE MIRROR BASE FRICTION WIRE 00 04 models Replacement page 20 33 Replacement page 20 34 R...

Page 1398: ...ove the door panel see page 20 7 4 Disconnect the connector A and detach the harness clip B then remove the bolts securing the mirror While holding the mirror C push out the clip D and remove the mirr...

Page 1399: ...1 Lower the door glass fully 2 Carefully pry out the mirror mount cover A by hand as shown 3 Remove the bolts securing the mirror While holding the mirror A push out the clip B and remove the mirror T...

Page 1400: ...release the hooks C D from the actuator adapter plate E while holding the mirror holder 3 If equipped disconnect the mirror defogger terminals A 4 Install the mirror holder in the reverse of the remo...

Page 1401: ...the rearview mirror base A 90 2 Slide the rearview mirror A down toward the bottom of the windshield to detach it from the spring B in the mount C 3 If necessary remove the spring from the mount 4 Ins...

Page 1402: ...for replacement or reinstallation LOWER CORNER FASTENER 2 Self adhesive type body side Required for replacement or reinstallation SEAL RUBBER DAM SIDE RUBBER DAM Required for replacement or reinstalla...

Page 1403: ...R GLASS OPENER Power type QUARTER GLASS ATTACHMENT RETAINER CLIP CAP SEAL RUBBER DAM UPPER SEAL MOLDING ATTACHMENT PIN QUARTER GLASS QUARTER GLASS HINGE BASE CLIP B 1 Self adhesive type glass side SLI...

Page 1404: ...ase pencil 4 Pull down the front portion of the headliner see page 20 62 Take care not to bend the headliner excessively or you may crease or break it 5 Apply protective tape A along the edge of the d...

Page 1405: ...e reinstalled use a putty knife to scrape off all of the old adhesive the rubber dam and the dashboard seal from the windshield Clean the shaded portion of the windshield A with alcohol where new adhe...

Page 1406: ...the edge of the windshield Be careful not to touch the windshield where adhesive will be applied 13 Attach the molding A with adhesive tape B 3M 4212 or equivalent to the edge of the windshield C Be s...

Page 1407: ...and molding side seal line up with the alignment dots C Be careful not to touch the windshield where adhesive will be applied 15 Install the fasteners to the body 16 Set the windshield in the opening...

Page 1408: ...ponges mixed up Never touch the primed surfaces with your hands If you do the adhesive may not bond to the windshield properly causing a leak after the windshield is installed Keep water dust and abra...

Page 1409: ...e way around Do not open or close the doors until the adhesive is dry 23 Scrape or wipe the excess adhesive off with a putty knife or towel To remove adhesive from a painted surface or the windshield...

Page 1410: ...indow defogger connectors A 3 If the old rear window will be reinstalled make alignment marks across the glass and body with a grease pencil 4 Apply protective tape A along the inside and outside edge...

Page 1411: ...ter from getting on the surface 9 If the old rear window will be reinstalled use a putty knife to scrape off all of the old adhesive and rubber dam from the rear window Clean the shaded portion of the...

Page 1412: ...r window where adhesive will be applied 13 Remove the rear window 14 With a sponge apply a light coat of glass primer along the edge of the rear window A lower rubber dam B as shown then lightly wipe...

Page 1413: ...rimer to the body and be careful not to mix up glass and body primer sponges Never touch the primed surfaces with your hands 16 Before filling a cartridge with adhesive cut a V in the end of the nozzl...

Page 1414: ...ark the leaking areas let the rear window dry then seal with sealant Let the vehicle stand for at least 4 hours after rear window installation If the vehicle has to be used within the first 4 hours it...

Page 1415: ...e sliding door glass 5 Carefully remove the sliding door glass 6 With a putty knife scrape the old adhesive smooth to a thickness of about 2 mm 0 08 in on the bonding surface around the entire sliding...

Page 1416: ...3M 4215 or equivalent to the inside surface of the glass C as shown Be careful not to touch the glass where adhesive will be applied 10 Apply primer 3M C 100 or equivalent to the molding tape area A...

Page 1417: ...lass where adhesive will be applied 14 With a sponge apply a light coat of glass primer along the edge of the glass A and molding B as shown then lightly wipe it off with gauze or cheesecloth Do not a...

Page 1418: ...nge Let the body primer dry for at least 10 minutes Do not apply glass primer to the body and be careful not to mix up glass and body primer sponges Never touch the primed surfaces with your hands 16...

Page 1419: ...a soft shop towel dampened with alcohol 20 Let the adhesive dry for at least 1 hour then spray water over the sliding door glass and check for leaks Mark any leaking areas let the sliding door glass d...

Page 1420: ...en prying with a flat tip screwdriver wrap it with protective tape and apply protective tape around the related parts to prevent damage Put on gloves to protect your hands 1 Remove the quarter glass a...

Page 1421: ...Hinge Base Replacement A B A A 1 Remove the plate A and turn the nut B as shown 2 Pull out the quarter glass hinge base A 3 Install the quarter glass hinge base on the body then set the quarter glass...

Page 1422: ...OPENING TRIM HEADLINER REAR CARPET TAILGATE SIDE TRIM TAILGATE UPPER TRIM TAILGATE TRIM PANEL KICK PANEL FRONT CARPET QUARTER PILLAR TRIM QUARTER GLASS OPENING TRIM REAR PILLAR TRIM page 20 58 page 2...

Page 1423: ...D D D LOWER ANCHOR COVER F Clip 1 D D D C 700 mm 27 6 in 03 04 models GROMMET RIGHT CENTER PILLAR LOWER TRIM PANEL HOOK DOOR OPENING TRIM KICK PANEL E E E D F NOTE Put on gloves to protect your hands...

Page 1424: ...ds When prying with a flat tip screwdriver wrap it with protective tape to prevent damage Take care not to bend or scratch the trim and panels 1 Remove the trim as shown 2 Install the trim in the reve...

Page 1425: ...EW SCREW NOTE Put on gloves to protect your hands When prying with a flat tip screwdriver wrap it with protective tape to prevent damage Take care not to bend or scratch the trim and panels 1 Remove t...

Page 1426: ...ing with a flat tip screwdriver wrap it with protective tape to prevent damage Take care not to bend or scratch the trim and panels Take care not to bend the lock rod 1 Remove the trim in the sequence...

Page 1427: ...nt seat belt upper anchor bolt both sides 2 Remove these items see page 20 59 Quarter pillar trim both sides Quarter glass opening trim both sides as necessary Rear pillar trim both sides 3 Third row...

Page 1428: ...s Ceiling light for some models see page 22 150 Cargo area light see page 22 151 9 For some 02 04 models Remove the rear controller and screen cover see page 22 343 10 Remove the rear A C passenger co...

Page 1429: ...ailgate opening 15 Install the headliner in the reverse order of removal and note these items When reinstalling the headliner through the tailgate opening be careful not to fold or bend it Also be car...

Page 1430: ...damage wrinkle or twist the carpet Be careful not to damage the dashboard or other interior trim pieces 1 Remove these items Front seats both sides see page 20 81 Center lower trim see page 20 67 Sec...

Page 1431: ...the clips and release the retainers A hook B and fasteners C then remove the front carpet D and rear carpet E Put on gloves to protect your hands 6 Install the carpet in the reverse order of removal...

Page 1432: ...ly protective tape around the related parts to prevent damage Take care not to scratch the dashboard and related parts 1 Remove the clips A and detach the clips B and tabs C then remove the center low...

Page 1433: ...before performing repairs or service NOTE Take care not to scratch the dashboard and related parts 1 Remove the center lower pocket see page 20 67 2 For some 02 04 models Remove the DVD player unit s...

Page 1434: ...E With navigation system disconnect the climate control unit connector 4 Install the instrument panel in the reverse order of removal and note these items Make sure each connector is plugged in prope...

Page 1435: ...se items Make sure each connector is plugged in properly if equipped Push the clips into place securely NOTE When prying with a flat tip screwdriver wrap it with protective tape and apply protective t...

Page 1436: ...dures see page 23 21 before performing repairs or service NOTE Take care not to scratch the dashboard and related parts If the glove box swings down without any support the hinges can be overextended...

Page 1437: ...pivot portion of the vent to the bushing first then push the right pivot portion into place securely NOTE Take care not to scratch the dashboard and related parts Put on gloves to protect your hands...

Page 1438: ...ation system then write down the frequencies for the preset buttons 2 Disconnect the negative battery cable and wait at least 3 minutes before beginning work 3 Remove these items Dashboard lower cover...

Page 1439: ...nector I ECM PCM connector 99 00 models or connectors 01 04 models J PCM subharness connector K 99 00 models evaporator temperature sensor connector L air mix control motor connector M recirculation c...

Page 1440: ...everse order of removal and note these items Make sure the dashboard fits onto the guide pins correctly Before tightening the bolts make sure the dashboard wire harness and steering hanger beam wire h...

Page 1441: ...73 2 Remove the following parts from the dashboard Instrument panel see page 20 69 Gauge assembly see page 22 100 Center lower console see page 20 68 Audio unit see page 22 159 Display unit with navig...

Page 1442: ...A A A A B A 5 Disconnect the dashboard wire harness connectors A SRS wire harness connector B cruise control connector C and keyless entry control unit connector D Remove the data link connector DLC...

Page 1443: ...t Fastener Locations A Screw 16 B Screw 6 C Screw 2 A A A B A A A A C C B B B B B A A A 8 From the front of the dashboard A remove the screws on the driver s side and the front passenger s airbag moun...

Page 1444: ...ts B steering hanger beam C and dashboard D 11 Install the steering hanger beam in the reverse order of removal and note these items Make sure the dashboard wire harness E and steering hanger beam wir...

Page 1445: ...Disassembly Reassembly 8 Way Power Without Side Airbag page 20 86 Disassembly Reassembly 8 Way Power With Side Airbag page 20 87 Disassembly Reassembly Manual Height Adjustable Without Side Airbag pag...

Page 1446: ...rap it with protective tape to prevent damage Take care not to scratch the body or tear the seat covers Put on gloves to protect your hands 1 For 02 04 models with side airbag Make sure you have the a...

Page 1447: ...ter weight sensor see step 6 on page 23 4 7 Slide the seat about halfway to the rear to access the front riser cover If equipped with an 8 way power seat fully raise the seat 8 For 99 02 models and 03...

Page 1448: ...01 model Manual height adjustable seat 02 model Manual height adjustable seat 03 04 models with side airbag 20 83 A To body A B A To body To body A B To body To body A B To body A B A To body A B To...

Page 1449: ...storage tray Manual seat all 03 04 models passenger s seat Manual seat 03 04 models passenger s seat without side airbag Manual seat 03 04 models passenger s seat with side airbag Without under seat s...

Page 1450: ...e any damaged clips Make sure each connector is plugged in properly Apply liquid thread lock to the seat mounting bolts before reinstallation Tighten the seat mounting bolts to the specified torque in...

Page 1451: ...35 lbf ft 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft POWER SEAT SWITCH SEAT CUSHION COVER 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft RECLINE COVER CLIP To seat cushion cover SWITCH KNOBS HEIGHT OUTER COVER...

Page 1452: ...HT INNER COVER SRS components are located in this area Review the SRS component locations 02 model see page 23 19 03 04 models see page 23 20 and the precautions and procedures see page 23 21 before p...

Page 1453: ...1 25 mm 47 N m 4 8 kgf m 35 lbf ft SEAT RISER WASHER 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft WASHER END CAP 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft CLIP 90 INNER...

Page 1454: ...T WASHER HOOKS BUSHING HEADREST SEAT BACK SEAT CUSHION CENTER COVER WIRE TIE CLIP SIDE AIRBAG HARNESS HOOK HOOKS END CAP 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft...

Page 1455: ...m 47 N m 4 8 kgf m 35 lbf ft WASHER 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft WASHER CENTER COVER For some models SRS compo...

Page 1456: ...ft UPPER END CAP CENTER COVER 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft 90 LOWER END CAP CONNECTING WIRE CONNECTING WIRE UPPER END CAP LOWER END CAP NOTE The passenger s seat is shown the driver s seat...

Page 1457: ...PASSENGER S SEAT SUBHARNESS With under seat storage tray HOOKS WIRE TIE SRS components are located in this area Review the SRS component locations see page 23 19 and the precautions and procedures see...

Page 1458: ...SS For some models OUTER WEIGHT SENSOR INNER WEIGHT SENSOR HARNESS BRACKET COVER CLIPS 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft WIRE TIE SRS components are located in this area Review the SRS component...

Page 1459: ...seat belt buckle B A C K J B J I J I C D K B A B A A B C D I J To seat cushion heater To power seat switch To seat belt buckle K C I J J J To seat belt buckle A I J When assembling the front seat make...

Page 1460: ...t 03 04 models without side airbag Manual height adjustable seat 03 04 models with side airbag Manual seat 99 02 models driver s seat 20 95 A A D I J K K D To seat belt buckle A I A I J K To seat belt...

Page 1461: ...de airbag and under seat storage tray Manual seat all 03 04 models passenger s seat Manual seat 03 04 models passenger s seat without side airbag 20 96 Seats Front Seat Wiring Harness Installation con...

Page 1462: ...th side airbag but no under seat storage tray Seat cushion Manual seat 03 04 models passenger s seat with side airbag and under seat storage tray 20 97 D K B A F K K K B A A C D G I J To seat cushion...

Page 1463: ...dels 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft 03 04 models 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft 03 model LOWER END CAP UPPER END CAP For 03 04 models The operation of the driver s seat position sens...

Page 1464: ...1 25 mm 22 N m 2 2 kgf m 16 lbf ft CLIPS CENTER TABLE INNER COVER CENTER TABLE CENTER TABLE ARM OUTER COVER SEAT RISER HOOK UNDER SEAT STORAGE TRAY For some models NAVIGATION UNIT CLIPS CLIPS UNDER S...

Page 1465: ...AT STORAGE TRAY For some models NAVIGATION UNIT For some models CLIPS CLIPS HOOK 8 x 1 25 mm 21 N m 2 1 kgf m 15 lbf ft 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft CLIPS Four places 6 x 1 0 mm 9 8 N m 1 0...

Page 1466: ...seat see page 20 81 2 Release the hooks from under the seat cushion then turn over the seat cushion cover as necessary see page 20 106 3 Put on gloves to protect your hands Remove the torsion bar A fr...

Page 1467: ...components Replacement of the seat weight sensors Replacement of the seat weight sensor unit NOTE With side airbag 02 04 models Seats with a side airbag have a Side Airbag label on the seat back Becau...

Page 1468: ...old the seat back forward 5 For 99 01 models Release the hook A and fold back the edge of the seat back cover B all the way around 6 For 02 04 models Release the hook A and unzip the seat back cover B...

Page 1469: ...Front Seat Cover Replacement cont d A B C A B A B B A A B 8 For some 02 04 models If equipped with side airbag release the hooks A of the reinforcing cloth B from the seat back frame C 9 Fold back the...

Page 1470: ...ack cover D 13 Install the cover in the reverse order of removal and note these items To prevent wrinkles when installing a seat back cover make sure the material is stretched evenly over the pad befo...

Page 1471: ...way power with side airbag see page 20 87 manual height adjustable without side airbag 01 model see page 20 88 manual height adjustable with side airbag 02 model see page 20 89 manual height adjustabl...

Page 1472: ...der of removal and note these items To prevent wrinkles when installing a seat cushion cover make sure the material is stretched evenly over the pad before securing the clips and hooks Replace any cli...

Page 1473: ...1 25 mm 21 N m 2 1 kgf m 15 lbf ft SLIDE ADJUSTER RISER ASSEMBLY TRACK END CORD TRACK END COVER 8 x 1 25 mm 21 N m 2 1 kgf m 15 lbf ft 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft TRACK END CORD SLIDE ADJ...

Page 1474: ...e HEADREST RIGHT RECLINE COVER RECLINE KNOB SEAT BACK RECLINE KNOB SEAT CUSHION RISER ASSEMBLY 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft 10 x 1 25 mm 47 N m 4 8 kgf m 35 lbf ft LEFT RECLINE COVER NOTE A...

Page 1475: ...COVER SPEED NUTS B B HOOK A Clip 4 Fastener Locations B Clip 4 RISER A A 10 x 1 25 mm 38 N m 3 9 kgf m 28 lbf ft 5 x 0 8 mm 8 x 1 25 mm 21 N m 2 1 kgf m 15 lbf ft 10 x 1 25 mm 38 N m 3 9 kgf m 28 lbf...

Page 1476: ...DAMPER HOOK OUTSIDE HOOK SPACER A B B SEAT BACK SEAT CUSHION CLIPS RELEASE KNOB ASSEMBLY Fastener Locations A Clip 2 B Clip 2 RELEASE KNOB ASSEMBLY CABLE Forward RISER LATCH A LEFT CONNECTING BRACKET...

Page 1477: ...nter pillar lower trim panel see page 20 58 Rear carpet as necessary see page 20 65 2 Remove the bolts and nut s then remove the striker A 3 Install the striker in the reverse order of removal NOTE Ta...

Page 1478: ...r B 7 For 99 01 models Release the hook A from behind the seat back 8 For 02 04 models Release the inside springs A from behind the seat back 9 For 02 04 models Release the clips A and fasteners B and...

Page 1479: ...e items To prevent wrinkles when installing a seat back cover make sure the material is stretched evenly over the pad before securing the fasteners and inside springs 02 04 models clips and hook Repla...

Page 1480: ...onal clips B that must be released near the child seat tether anchors Then remove the seat cushion cover C 6 Install the cover in the reverse order of removal and note these items To prevent wrinkles...

Page 1481: ...eat 3 Remove these items Recline cover both sides see page 20 109 Armrest and armrest pins both sides see step 1 on page 20 102 4 Release the hook A in the bottom of the seat back cover B then raise t...

Page 1482: ...revent wrinkles when installing a seat back cover make sure the material is stretched evenly over the pad before securing the hook and clips Replace any clips A you removed with new ones using commerc...

Page 1483: ...A then remove the seat cushion cover B 6 Install the cover in the reverse order of removal and note these items To prevent wrinkles when installing a seat cushion cover make sure the material is stret...

Page 1484: ...ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 lbf ft A B C NOTE Take care not to scratch the interior trim and body or tear the seat covers 1 Remove the third row seat as shown 2 Install the seat in the reverse...

Page 1485: ...cline cables Put on gloves to protect your hands 1 Remove the screws and remove the recline lever trim A from behind the seat back 2 Remove the screw and release the hook A then remove the recline upp...

Page 1486: ...eams or damage the seat covers Take care not to kink the cushion latch cables Put on gloves to protect your hands 1 Remove the third row seat through the tailgate opening see page 20 119 2 Remove the...

Page 1487: ...ver in the reverse order of removal and note these items Make sure the cushion latch cables are connected securely Make sure the third row seat latches and unlatches properly NOTE When prying with a f...

Page 1488: ...vailable upholstery ring pliers B NOTE When prying with a flat tip screwdriver wrap it with protective tape to prevent damage Take care not to bend the cables Take care not to kink or scratch the inte...

Page 1489: ...hese items Recline lever trim see page 20 120 Recline upper cover see step 2 on page 20 120 2 For 02 04 models From both sides pry up the cap A and remove the screws then remove the cushion hooks B Re...

Page 1490: ...e the clips B and fasteners C 02 04 models leather seat 8 Lift and pull out the release buttons A and remove the screws B then remove all the headrest guide C D 9 Remove the seat back cover E 10 Insta...

Page 1491: ...shion latch cover see step 2 on page 20 122 Cushion latch lever trim see page 20 121 3 Remove the screws then remove the grab handle A from the cushion frame 4 For 02 04 models Pry up the caps A and r...

Page 1492: ...reverse order of removal and note these items To prevent wrinkles make sure the material is stretched evenly over the pad before securing all the clips Replace the clips fastening the seat cushion ma...

Page 1493: ...body Put on gloves to protect your hands 1 Remove the front bulkhead cover see page 20 142 2 Remove the front bumper A 1 Remove the bolts B and clips C securing the front bumper inner fender D and spl...

Page 1494: ...s A B then remove the front bumper beam C and both corner upper beams D If necessary remove the absorber E 4 Install the front bumper in the reverse order of removal and note these items Make sure the...

Page 1495: ...Remove the taillights see page 22 132 2 Remove the rear bumper A 1 Pry out the caps B and remove the bolts C from each side 2 Remove the screws D securing the rear bumper and rear clip E from each si...

Page 1496: ...ve the nuts A and bolts B then remove the rear bumper beam C If necessary remove the absorber D 5 Install the rear bumper in the reverse order of removal and note these items Make sure the rear bumper...

Page 1497: ...you when removing and installing the hood Take care not to damage the hood and body 1 Remove the hood as shown For 02 04 models remove the hood insulator as necessary see page 20 134 2 Install the hoo...

Page 1498: ...uence Adjust the hood right and left as well as forward and rearward by using the elongated holes on the hood hinge A Turn the hood edge cushions B as necessary to make the hood fit flush with the bod...

Page 1499: ...nd around the hinges 7 Remove the front bulkhead cover see page 20 142 and Apply multipurpose grease to the hood latch and hood hinge as indicated by the arrows 1 Using a clip remover detach the clips...

Page 1500: ...mover detach the clips A B then remove the hood seal C and hood sub seal D On Canadian models detach the clips E then remove the hood molding F Take care not to scratch the hood 2 Install the seal and...

Page 1501: ...tect your hands 1 Remove the tailgate trim panel see page 20 61 2 Remove the tailgate spoiler see page 20 140 3 Disconnect the tailgate harness connectors A and rear window defogger connector B Detach...

Page 1502: ...help of an assistant remove the bolts then remove the tailgate E Take care not to damage the tailgate and body 6 Install the tailgate in the reverse order of removal and note these items Make sure th...

Page 1503: ...sequence Pull down the rear portion of the headliner see page 20 62 Take care not to bend the headliner excessively Adjust the tailgate hinges A right and left as well as forward and rearward using th...

Page 1504: ...8 Apply multipurpose grease to the pivot portion of the tailgate hinges A as indicated by the arrows 1 With the help of an assistant use a flat tip screwdriver A to pry the support strut clips B from...

Page 1505: ...gate and detach the clip C 3 Gently close the tailgate and lift up on the tailgate spoiler A Remove the high mount brake light connector grommet B from the tailgate and disconnect the high mount brake...

Page 1506: ...t B into the channel of the tailgate weatherstrip all the way around 3 Locate the painted alignment mark C on the tailgate weatherstrip Align the painted mark with the alignment tab in the the center...

Page 1507: ...with protective tape to prevent damage Take care not to scratch the front bulkhead cover and front grille 1 Detach the clips then remove the front bulkhead cover A 2 Detach the clips then remove the...

Page 1508: ...20 143 Front Grille Disassembly Reassembly Fastener Locations Screw 18 FRONT GRILLE EMBLEM MOLDING SPEED NUTS NOTE Take care not to scratch the front grille and molding Replace...

Page 1509: ...of the tailgate 26 1 02 H EMBLEM Center H EMBLEM Edge of the tailgate 15 0 59 NOTE When removing the emblems take care not to scratch the tailgate Use dental floss to cut the adhesive safely Apply the...

Page 1510: ...ding them in the direction shown while pushing the spring plate C through the hole on each bracket with a flat tip screwdriver Remove the center cap D then with a Torx T30 bit remove the nuts F from t...

Page 1511: ...ent Replace the roof molding when the steel core is bent 1 Remove the roof rail and center bracket see page 20 145 2 Using a flat tip screwdriver wrapped with protective tape and a shop towel on the b...

Page 1512: ...are to release the molding clips from inside the vehicle To remove the front door molding remove the front door panel and plastic cover see page 20 7 To remove the sliding door molding remove the slid...

Page 1513: ...ack as necessary 3 Slide the side sill panel C forward and remove it Side clips D will stay in the body 4 Remove the side clips from the body 2 Replace any damaged clips 3 Install the side clips on th...

Page 1514: ...Replace any damaged clips Push the clips into place securely 1 Remove the fenderwell trim A by carefully pulling it out NOTE The steel core B in the fenderwell trim cannot be restored to it original s...

Page 1515: ...ear Air Outlet Replacement B A A 1 Remove the rear bumper see page 20 130 2 Detach the hooks A then remove the rear air outlet B Take care not to scratch the body 3 Install the air outlet in the rever...

Page 1516: ...H FUEL FILL DOOR OPENER HOOD RELEASE HANDLE HOOD LATCH TAILGATE HANDLE FUEL FILL DOOR OPENER CABLE Replacement page 20 158 Replacement page 20 152 Replacement page 20 158 Replacement page 20 156 Repla...

Page 1517: ...page 20 58 2 Remove the hood latch A see page 20 154 and disconnect the hood opener B 3 Remove the hood release handle C see page 20 154 and disconnect the hood opener cable 4 Using a clip remover de...

Page 1518: ...oor sill trim left side see page 20 58 Rear side trim panel see page 20 60 Third row seat belt retractor see page 23 11 2 Pull the carpet back as necessary see page 20 65 3 Disconnect the fuel fill do...

Page 1519: ...he hood release handle B Take care not to kink the cable 4 Install the handle in the reverse order of removal and note there items Make sure the hood opener cable is connected properly Make sure the h...

Page 1520: ...ly and the hood latch switch connector is properly connected Make sure the cable actuates the latch before you close the hood Adjust the hood latch alignment see step 3 on page 20 133 Make sure the ho...

Page 1521: ...ese items Make sure the opener cable is connected properly Make sure the fuel fill door opens properly Check the operation of the sliding door verify that the left sliding door locks when the fuel fil...

Page 1522: ...door verify that the left sliding door locks when the fuel filler door release is pulled 4 Check that the fuel fill door fits flush against the body If necessary adjust it 5 Apply touch up paint to th...

Page 1523: ...r of removal and note these items Make sure the connectors are plugged in properly and the each rod is connected properly Make sure the cable actuates the latch before you close the tailgate Make sure...

Page 1524: ...placement SPARE TIRE WELL ACCESS PANEL Fastener Locations Bolt 2 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft SPARE TIRE WELL ACCESS PANEL 1 Remove the spare tire well access panel as shown 2 Install the a...

Page 1525: ...BRACKET 12 x 1 25 mm 74 N m 7 5 kgf m 54 lbf ft FRONT SUSPENSION SUBFRAME FRONT SUSPENSION SUBFRAME REAR BRACKET 12 x 1 25 mm 117 N m 11 9 kgf m 86 1 lbf ft To body To body To body To body SUBFRAME R...

Page 1526: ...bf ft To body REAR SUSPENSION SUBFRAME To body INSTALLATION REFERENCE HOLE SUBFRAME REFERENCE HOLE Body side SCREWDRIVER or TAPERED PUNCH INSTALLATION REFERENCE HOLE Subframe side INSTALLATION REFEREN...

Page 1527: ...Top View 20 162 Frame Frame Repair Chart...

Page 1528: ...20 163 cont d...

Page 1529: ...Side View 20 164 Frame Frame Repair Chart cont d...

Page 1530: ...20 165...

Page 1531: ...tified by yellow color coding Related components are located in the steering column front console dashboard dashboard lower panel in the dashboard above the glove box in the front seats and around the...

Page 1532: ...est 21 60 Component Location Index 21 64 General Troubleshooting Infomation 21 67 DTC Troubleshooting Index 21 71 Symptom Troubleshooting Index 21 72 System Description 21 73 Circuit Diagram 21 76 DTC...

Page 1533: ...Ref No Tool Number Description Qty 21 2 HVAC Heating Ventilation and Air Conditioning Special Tools 07SAZ 001000A Backprobe Set 2 03 07 29 10 09 36 61S0X050_210_0003...

Page 1534: ...CONDENSER EVAPORATOR COMPONENTS SERVICE VALVE LOW PRESSURE SIDE cont d Removal and Installation page 21 42 Replacement page 21 49 Clutch Check page 21 51 Clutch Overhaul page 21 52 Relief Valve Replac...

Page 1535: ...A C DIODE C Located under dash taped to harness UNDER HOOD FUSE RELAY BOX BLOWER MOTOR RELAY CONDENSER FAN RELAY RADIATOR FAN RELAY A C COMPRESSOR CLUTCH RELAY ABS RELAY BOX FAN CONTROL RELAY A C DIOD...

Page 1536: ...SWITCH HEATER CONTROL PANEL HEATER FAN SWITCH Test page 21 39 Replacement page 21 39 Removal and Installation page 21 45 Replacement page 21 45 Adjustment page 21 48 Replacement page 21 44 Removal and...

Page 1537: ...ative cable from the battery whenever replacing air conditioning parts Keep moisture and dirt out of the system When disconnecting any lines plug or cap the fittings immediately don t remove the caps...

Page 1538: ...compressor 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 lbf ft Compressor bracket to the engine block 10 x 1 25 mm 44 N m 4 5 kgf m 33 lbf ft Compressor to the compressor bracket 8 x 1 25 mm 22 N m 2 2 kgf m 16 l...

Page 1539: ...II 2 Turn the fan switch OFF 3 Press the recirculation control button to select Recirculation recirculation indicator comes on 4 Press and hold the recirculation control button to select Fresh recircu...

Page 1540: ...roblem in the mode control motor circuit see page 21 17 3 A problem in the evaporator temperature sensor circuit see page 21 19 In case of multiple problems the recirculation indicator will indicate o...

Page 1541: ...do not run at low speed with the A C on when the refrigerant pressure is below 1 520 kPa 15 5 kgf cm 220 psi Radiator and condenser fan low speed circuit troubleshooting see page 21 27 HVAC DTCs see p...

Page 1542: ...dryer expansion valve O rings for joints are designed for refrigerant R 134a Do not exchange with R 12 parts Use a halogen gas leak detector designed for refrigerant R 134a R 12 and R 134a refrigerant...

Page 1543: ...A C pressure switch consists of a high low pressure switch A C pressure switch A and a middle pressure switch A C pressure switch B High Low pressure switch If the refrigerant pressure becomes too hi...

Page 1544: ...YEL MODE 2 INPUT 9 BLK GROUND G401 INPUT 10 RED BLK COMBINATION LIGHT SWITCH or TAILLIGHT RELAY INPUT 11 GRN RED FRESH OUTPUT 12 RED YEL AIR MIX HOT OUTPUT 13 RED WHT AIR MIX COOL OUTPUT 14 BLU WHT M...

Page 1545: ...7 30A 4 1 4 1 RED 2 3 3 2 UNDER HOOD FUSE RELAY BOX YEL WHT No 41 120A BATTERY PCM ACC G201 G201 1 2 1 2 G101 BLK BLU RED 1 2 RED BLK BLK BLU BLK BLU YEL IGNITION SWITCH IG2 HOT in ON II DRIVER S UNDE...

Page 1546: ...D YEL RED WHT IG2 S COM S COM 5V BRN YEL RED BLK M COOL AMD P S5V M HOT BLK YEL MODE3 MODE2 MODE1 M DEF M VENT REC FRS 5V 8 5 3 17 7 18 1 11 9 4 10 7 5 1 LT GRN BLK GRN YEL GRN WHT BLK GRN RED YEL GRN...

Page 1547: ...tween body ground and the heater control panel 22P connector terminals No 12 13 16 17 and 19 individually Repair any short to body ground in the wire s between the heater control panel and the air mix...

Page 1548: ...r control panel Repair any open in the wire s between the heater control panel and the air mix control motor 8 Remove the air mix control motor see page 21 37 9 Check the air mix control linkage and d...

Page 1549: ...efore replacing the heater control panel Go to step 6 6 Turn the ignition switch off 7 Check for continuity between following terminals of the heater control panel 22P connector and the mode control m...

Page 1550: ...linkage or doors 1 Disconnect the evaporator temperature sensor 2P connector 2 Measure the resistance between the No 1 and No 2 terminals of the evaporator temperature sensor Go to step 3 Replace the...

Page 1551: ...onnector Go to step 6 Repair open in the wire between the heater control panel and the evaporator temperature sensor 6 Check for continuity between the No 17 terminal of the heater control panel 22P c...

Page 1552: ...6 Test the recirculation control motor see page 21 39 Go to step 7 Go to step 12 7 Disconnect the heater control panel 22P connector 8 Check for continuity between the No 1 and No 11 terminals of the...

Page 1553: ...irculation control motor 12 Remove the recirculation control motor see page 21 39 13 Check the recirculation control linkage and doors for smooth movement Replace the recirculation control motor Repai...

Page 1554: ...7P connector terminals individually in the following order No 3 4 5 and 6 Replace the heater fan switch Repair any open or cause of excessive resistance in the appropriate wire s between the blower re...

Page 1555: ...n the wire between the blower motor and the heater fan switch 25 Turn the ignition switch OFF 26 Check for continuity between the No 1 terminal of the heater fan switch 7P connector and body ground Re...

Page 1556: ...ion switch ON II 34 Measure the voltage between the No 1 terminal of the blower motor relay 4P socket and body ground Go to step 35 Repair open in the wire between the No 3 fuse in the driver s under...

Page 1557: ...box and the heater control panel 5 Turn the ignition switch OFF 6 Measure the voltage between the No 3 terminal of the heater control panel 22P connector and body ground Go to step 7 Repair open in t...

Page 1558: ...condenser fan relay from the under hood fuse relay box and test it see page 22 88 Go to step 3 Replace the condenser fan relay 3 Measure the voltage between the No 1 terminal of the condenser fan rela...

Page 1559: ...ode A and the A C pressure switch Repair open in the wire between the condenser fan relay and A C diode A 13 Disconnect the jumper wire 14 Reinstall the condenser fan relay 15 Disconnect the condenser...

Page 1560: ...ocket and body ground Go to step 27 Repair open in the wire between the condenser fan and the fan control relay 27 Turn the A C and fan switches OFF then turn the ignition switch OFF 28 Disconnect the...

Page 1561: ...ABS relay box and test it see page 22 88 Go to step 3 Replace the fan control relay 3 Turn the ignition switch ON II 4 Measure the voltage between the No 5 terminal of the fan control relay 5P socket...

Page 1562: ...tween the No 2 terminal of A C diode C 2P socket and body ground Go to step 5 Repair open in the wire between the radiator fan relay and A C diode C 5 Turn the ignition switch OFF 6 Reinstall A C diod...

Page 1563: ...ible Sensor 99 01 models 163 194 F 73 90 C 02 04 models 169 194 F 76 90 C TPS About 0 5 V RPM More than 730 Go to step 3 Troubleshoot and repair cause of high engine coolant temperature low idle or ex...

Page 1564: ...l the compressor clutch relay 11 Make sure the A C switch is OFF 12 Turn the ignition switch ON II 13 99 00 and 02 04 models Using the Backprobe Set measure the voltage between the No 17 terminal of P...

Page 1565: ...oor connections at PCM connector A 32P or E 31P If the connections are good substitute a known good PCM and recheck If the symptom indication goes away replace the original PCM Repair open in the wire...

Page 1566: ...the A C pressure switch 4P connector and body ground Go to step 4 Repair open in the wire between A C diode A the PCM and the A C pressure switch 4 Turn the ignition switch OFF 5 Check for continuity...

Page 1567: ...switch see page 21 40 Go to step 15 Replace the heater fan switch 15 Check for continuity between the No 1 terminal of the heater fan switch 7P connector and body ground Check for loose wire or poor c...

Page 1568: ...move smoothly replace the air mix control motor If the linkage or door sticks or binds repair them as needed If the air mix control motor runs smoothly go to step 4 4 Measure the resistance between t...

Page 1569: ...ent If the linkage and doors move smoothly replace the mode control motor If the linkage or doors stick or bind repair them as needed If the mode control motor runs smoothly go to step 4 4 Use a digit...

Page 1570: ...al is disconnected or Recirculate when the No 5 terminal is disconnected Don t cycle the recirculation control motor for a long time 3 If the recirculation control motor did not run in step 2 remove i...

Page 1571: ...5 6 HEATER FAN SWITCH 1 Dip the sensor in ice water and measure the resistance between its terminals 2 Then pour warm water on the sensor and check for a change in resistance 3 Compare the resistance...

Page 1572: ...control panel in the reverse order of removal After installation operate the control panel controls to see whether it works properly 4 Run the self diagnosis function to confirm that there are no pro...

Page 1573: ...ve the wire harness connectors A Disconnect the evaporator temperature sensor connector B Remove the self tapping screws the mounting nuts the mounting bolts the bracket C and the evaporator D 6 Insta...

Page 1574: ...e the expansion valve G 5 Reassemble the evaporator in the reverse order of disassembly and note these items Replace all O rings with new ones at each fitting and apply a thin coat of refrigerant oil...

Page 1575: ...see page 20 71 2 Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown and discard it 3 Remove the bolts the screws and the glove box frame 4 Remove the filter l...

Page 1576: ...and the recirculation control motor then remove the wire harness clips B Remove the mounting nuts the mounting bolt and the blower unit C 6 Install the unit in the reverse order of removal and note t...

Page 1577: ...m the battery 3 From under the hood open the cable clamp A then disconnect the heater valve cable B from the heater valve arm C Turn the heater valve arm to the fully opened position as shown 4 When t...

Page 1578: ...nd note these items Do not interchange the inlet and outlet heater hoses and install the hose clamps securely Refill the cooling system with engine coolant see page 10 13 Adjust the heater valve cable...

Page 1579: ...trol dial or button on Max Cool 60 F or 18 C with the ignition switch ON II 4 Attach the heater valve cable B to the air mix control linkage C as shown step 2 Hold the end of the heater valve cable ho...

Page 1580: ...radio s preset buttons 3 Disconnect the negative cable from the battery 4 Recover the refrigerant with a recovery recycling charging station see page 21 56 5 Remove the alternator see page 4 27 6 Remo...

Page 1581: ...8 for HFC 134a DENSO piston type compressor only To avoid contamination do not return the oil to the container once dispensed and never mix it with other refrigerant oils Immediately after using the...

Page 1582: ...s excessive play drag see page 21 52 3 Measure the clearance betweenn the pulley A and the pressure plate B with a dial indicator Zero out the indicator then apply battery voltage to the compressor cl...

Page 1583: ...the shim s If the clutch needs adjustment increase or decrease the number and thickness of shims as necessary then reinstall the pressure plate and recheck its clearance see page 21 51 NOTE The shims...

Page 1584: ...re they are fully seated in the groove Make sure that the pulley turns smoothly after it s reassembled Route and clamp the wires properly or they can be damaged by the rotor pulley 1 Recover the refri...

Page 1585: ...er by lifting it up Be careful not to damage the radiator or the condenser fins when removing the condenser 6 Install the condenser in the reverse order of removal and note these items If you re insta...

Page 1586: ...tom of the condenser then remove the O rings B the filter C and the desiccant D 3 Install the desiccant in the reverse order of removal Replace the O rings with new ones and apply a thin coat of refri...

Page 1587: ...ccidental system discharge occurs ventilate work area before resuming service Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 13...

Page 1588: ...ers 1 When an A C System has been opened to the atmosphere such as during installation or repair it must be evacuated using a R 134a refrigerant recovery recycling charging station If the system has b...

Page 1589: ...tilate work area before resuming service Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recovery recycling cha...

Page 1590: ...ng system If accidental system discharge occurs ventilate work area before resuming service R 134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested wi...

Page 1591: ...ssed air Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recovery recycling charging station to the high pressu...

Page 1592: ...4 300 3 200 2 100 1 500 5 3400 35 500 430 360 280 210 140 71 57 43 28 14 500 430 360 280 210 140 71 57 43 28 14 2 2 2 2 8 To complete the charts Mark the delivery temperature along the vertical line M...

Page 1593: ...ture is low and the airflow from vents is restricted Frozen evaporator Run the fan with compressor off then check evaporator temperature sensor Expansion valve is frosted Clogged expansion valve Clean...

Page 1594: ...21 63...

Page 1595: ...ess UNDER HOOD FUSE RELAY BOX BLOWER MOTOR RELAY CONDENSER FAN RELAY RADIATOR FAN RELAY A C COMPRESSOR CLUTCH RELAY ABS RELAY BOX FAN CONTROL RELAY A C DIODE A PASSENGER S UNDER DASH FUSE RELAY BOX OU...

Page 1596: ...LIGHT SENSOR BLOWER MOTOR HIGH RELAY cont d Test page 21 39 Replacement page 21 39 Removal and Installation page 21 45 Replacement page 21 45 Adjustment page 21 48 Replacement page 21 44 Removal and I...

Page 1597: ...WER MOTOR HIGH RELAY CLIMATE CONTROL UNIT HEATER VALVE CABLE HEATER UNIT CORE SUNLIGHT SENSOR Test page 21 39 Replacement page 21 39 Removal and Installation page 21 45 Replacement page 21 45 Replacem...

Page 1598: ...Indicator will light up the segment A through N corresponding to the error The temperature indicator will then alternate every second between displaying 88 all segments lit and the error code segment...

Page 1599: ...nction press the recirculation button to switch from FRESH to RECIRC The air volume and sound should change slightly 2 Set the temperature control knob to the desired test temperature When selecting t...

Page 1600: ...Value Dark 00 Flashlight 04 Cloudy 10 Sunny 65 Kcal m2 h 5 Engine coolant Temperature C 6 Evaporator Outlet Air Temperature C 7 Air Mix Opening Low value indicates cooler air distribution higher valu...

Page 1601: ...0 122 60 140 70 158 80 176 90 194 51 124 61 142 71 160 81 178 91 196 52 126 62 144 72 162 82 180 92 198 53 127 63 145 73 163 83 181 93 199 54 128 64 147 74 165 84 183 94 201 55 131 65 149 75 167 85 18...

Page 1602: ...2 D A short in the outside air temperature sensor circuit see page 21 85 E An open in the sunlight sensor circuit see page 21 86 F A short in the sunlight sensor circuit see page 21 88 G An open in th...

Page 1603: ...ns do not run at low speed with the A C on when the refrigerant pressure is below 1 520 kPa 15 5 kgf cm 220 psi Radiator and condenser fan low speed circuit troubleshooting see page 21 27 HVAC DTCs se...

Page 1604: ...GROUND G401 INPUT 1 PNK BLK AIR MIX POTENTIAL INPUT 2 RED WHT A C PRESSURE SWITCH OUTPUT 3 GRN RED FRESH OUTPUT 4 GRN WHT RECIRCULATE OUTPUT 5 BLU BLK MODE DEF OUTPUT 6 BLU WHT MODE VENT OUTPUT 7 RED...

Page 1605: ...SENSOR COMMON GROUND OUTPUT 2 GRN WHT FL OUTPUT 3 GRY AIR MIX POTENTIAL 5 V OUTPUT 4 RED WHT A C PRESSURE SWITCH OUTPUT 5 GRN BLK MODE 1 INPUT 6 GRN YEL MODE 2 INPUT 7 LT GRN BLK MODE 3 INPUT 8 BLU G...

Page 1606: ...21 75...

Page 1607: ...T No 41 120A BATTERY PCM GRN BLK RED WHT ACC 5 4 G201 G201 5V 1 2 1 2 G101 BLK BLU RED 1 2 RED RED WHT BLK BLK BLU BLK SG2 ECT BLU YEL IGNITION SWITCH IG2 HOT in ON II DRIVER S UNDER DASH FUSE RELAY B...

Page 1608: ...OM S COM 5V BRN YEL RED BLK M COOL AMD P S5V M HOT BLK YEL MODE3 MODE2 MODE1 M DEF M VENT REC FRS 12V 19 2 11 18 20 4 3 8 8 7 5 1 LT GRN BLK GRN YEL GRN WHT BLK GRN RED YEL GRN BLU WHT GRN BLK BLU BLK...

Page 1609: ...WHT No 41 120A BATTERY PCM RED WHT ACC 5 4 G201 G201 5V 1 2 1 2 G101 BLK BLU RED 1 2 RED RED WHT BLK BLK BLU BLK SG2 ECT BLU YEL IGNITION SWITCH IG2 HOT in ON II DRIVER S UNDER DASH FUSE RELAY BOX RA...

Page 1610: ...16 RED GRN 5V 5V 4 2 SO CLK2 SI 3 ILLUMI 2 IG 6 FL 7 FL LATCH 4 CLK1 5 DATA 13 12V 15 DS1 16 DS0 14 DS2 D2 8 D1 9 D0 10 OFF AUTO 11 D GND 1 RED BLK BLK YEL BLK WHT 16 8 BRN WHT BLU 7 WHT BLK 6 WHT YE...

Page 1611: ...Check for continuity between the No 16 terminal of climate control unit connector B 20P and the No 2 terminal of the in car temperature sensor 2P connector Go to step 5 Repair open in the wire betwee...

Page 1612: ...control unit and recheck If the symptom indication goes away replace the original climate control unit Repair open in the wire between the climate control unit and the in car temperature sensor 1 Remo...

Page 1613: ...good climate control unit and recheck If the symptom indication goes away replace the original climate control unit 1 Remove the outside air temperature sensor see page 21 118 2 Measure the resistance...

Page 1614: ...ity between the No 11 terminal of climate control unit connector B 20P and the No 2 terminal of the outside air temperature sensor 2P connector Check for loose wires or poor connections at climate con...

Page 1615: ...outside air temperature sensor 8 Check for continuity between the No 1 terminal of climate control unit connector B 26P and the No 2 terminal of the outside air temperature sensor 2P connector Check f...

Page 1616: ...ody ground in the wire between the climate control unit and the outside air temperature sensor Substitute a known good climate control unit and recheck If the symptom indication goes away replace the...

Page 1617: ...11 terminal of climate control unit connector B 20P and the No 2 terminal of the sunlight sensor 2P connector Go to step 5 Repair open in the wire between the climate control unit and the outside air...

Page 1618: ...minal of the sunlight sensor 2P connector Go to step 11 Repair open in the wire between the climate control unit and the outside air temperature sensor 11 Reconnect the sunlight sensor 2P connector 12...

Page 1619: ...a known good climate control unit and recheck If the symptom indication goes away replace the original climate control unit Replace the sunlight sensor 7 Disconnect climate control unit connector B 2...

Page 1620: ...ensor Without Navigation System Go to step 3 With Navigation System Go to step 6 Replace the evaporator temperature sensor 3 Disconnect climate control unit connector B 20P 4 Check for continuity betw...

Page 1621: ...tor If the connections are good substitute a known good climate control unit and recheck If the symptom indication goes away replace the original climate control unit Repair open in the wire between t...

Page 1622: ...porator temperature sensor 1 Disconnect the evaporator temperature sensor 2P connector 2 Test the evaporator temperature sensor see page 21 40 Without Navigation System Go to step 3 With Navigation Sy...

Page 1623: ...unit connector B 20P 3 Check for continuity between following terminals of climate control unit connector B 20P and the air mix control motor 7P connector 20P 7P No 1 No 3 No 7 No 2 No 9 No 1 No 11 No...

Page 1624: ...mptom indication goes away replace the original air mix control motor If the symptom indication continues substitute a known good climate control unit and recheck If the symptom indication goes away r...

Page 1625: ...Substitute a known good air mix control motor and recheck If the symptom indication goes away replace the original air mix control motor If the symptom indication continues substitute a known good cli...

Page 1626: ...or If the symptom indication continues substitute a known good climate control unit and recheck If the symptom indication goes away replace the original climate control unit 1 Test the air mix control...

Page 1627: ...ity between body ground and climate control unit connector B 20P terminals No 5 6 11 17 18 19 and 20 individually Repair any short to body ground in the wire s between the climate control unit and the...

Page 1628: ...ontinues substitute a known good climate control unit and recheck If the symptom indication goes away replace the original climate control unit Repair any open in the wire s between the climate contro...

Page 1629: ...re replacing the climate control unit Go to step 8 8 Turn the ignition switch OFF and check for continuity between following terminals of climate control unit connector B 26P and the mode control moto...

Page 1630: ...s for smooth movement Replace the mode control motor Repair the mode control linkage or doors 1 Turn the ignition switch ON II and turn the blower fan speed knob to HIGH Go to step 2 Go to step 20 2 T...

Page 1631: ...ep 8 8 Disconnect climate control unit connector A 8P 9 Check for continuity between the No 5 terminal of climate control unit connector A 8P and the No 3 terminal of the power transistor 5P connector...

Page 1632: ...in the wire between the climate control unit and the power transistor Go to step 18 13 Disconnect climate control unit connector B 26P 14 Check for continuity between the No 12 terminal of climate con...

Page 1633: ...A 8P or B 26P 19 Test the power transistor see page 21 120 Check for loose wires or poor connections at climate control unit connector A 8P or B 26P and at the power transistor 5P connector If the con...

Page 1634: ...nect the jumper wire 30 Turn the ignition switch ON II 31 Measure the voltage between the No 1 terminal of the blower motor high relay 5P connector and body ground Go to step 32 Repair the open in the...

Page 1635: ...goes away replace the original climate control unit Repair open in the wire between the climate control unit and the blower motor high relay 36 Disconnect climate control unit connector A 16P 37 Check...

Page 1636: ...fuse relay box and test it see page 22 88 Go to step 43 Replace the blower motor relay 43 Measure the voltage between the No 4 terminal of the blower motor relay 4P socket and body ground Go to step...

Page 1637: ...r lamp MIL Refer to the powertrain DTCs see page 11 3 Without Navigation System Go to step 2 With Navigation System Go to step 7 2 Turn the ignition switch OFF 3 Disconnect the ECT sensor 2P connector...

Page 1638: ...ol unit Repair open in the wire between the climate control unit and the ECT sensor 1 Check the No 3 7 5A fuse in the driver s under dash fuse relay box Go to step 2 Replace the fuse and recheck 2 Dis...

Page 1639: ...ulation control motor This short may also damage the climate control unit Repair the short to power before replacing the climate control unit Go to step 10 10 Turn the ignition switch off 11 Check for...

Page 1640: ...step 15 15 Turn the ignition switch OFF 16 Check for continuity between the following terminals of climate control unit connector B 26P and the recirculation control motor 7P connector 26P 7P No 23 No...

Page 1641: ...witch 4P connector 2 Turn the ignition switch ON II 3 Measure the voltage between the No 1 terminal of the A C presure switch 4P connector and body ground Go to step 4 Repair open in the wire between...

Page 1642: ...nect climate control unit connector B 26P 11 Turn the ignition switch ON II 12 Measure the voltage between the No 4 terminal of climate control unit connector B 26P and body ground Check for loose wir...

Page 1643: ...elay box and the climate control unit 5 Turn the ignition switch OFF 6 Measure the voltage between the No 2 terminal of climate control unit connector A 8P and body ground Go to step 7 Repair open in...

Page 1644: ...unit 11 Turn the ignition switch OFF 12 Check for continuity between the No 15 terminal of climate control unit connector B 26P and body ground Check for loose wires or poor connections at climate co...

Page 1645: ...climate control panel 16P connector and body ground Go to step 5 Repair open in the wire between the No 3 fuse in the driver s under dash fuse relay box and the climate control panel 5 Turn the ignit...

Page 1646: ...ections are good substitute a known good climate control panel and go to step 9 9 Reconnect the climate control panel 16P connector 10 Reconnect climate control unit connectors A 16P and B 26P 11 Turn...

Page 1647: ...Go to step 4 Repair any open in the wire s between the climate control unit and the navigation display unit 4 Check for continuity between the No 14 15 and 16 terminals of climate control unit connect...

Page 1648: ...sensor with a hair drier Compare the resistance reading between the No 1 and No 2 terminals of the in car temperature sensor with the specifications shown in the graph the resistance should be within...

Page 1649: ...water on the sensor and check for a change in resistance Compare the resistance reading between the No 1 and No 2 terminals of the outside air temperature sensor with the specifications shown in the...

Page 1650: ...he 2P connector connected The voltage reading will not change under the light of a flashlight or a fluorescent lamp Voltage should be 3 6 3 7 V or more with the sensor out of direct sunlight 3 3 3 5 V...

Page 1651: ...inal and insulate it from body ground 4 Connect a 1 2 3 4 W bulb B between the No 3 and the No 4 cavity on the 5P connector 5 Reconnect the 5P connector to the power transistor 6 Turn the ignition swi...

Page 1652: ...anel in the reverse order of removal After installation operate the climate control panel to see whether it works properly 4 Run the self diagnosis function to confirm that there are no problems in th...

Page 1653: ...REAR BLOWER MOTOR MAIN RELAY REAR MODE CONTROL MOTOR RELAY MULTI FUSE RELAY BOX 99 02 models UNDER HOOD SUB FUSE BOX 03 04 models REAR BLOWER RESISTOR HIGH RELAY MAIN RELAY MODE CONTROL MOTOR RELAY MI...

Page 1654: ...esistor Open in the wire Poor ground at G582 Cleanliness and tightness of all connectors Rear blower motor does not run on low middle and high for heating but runs on high for cooling Rear blower moto...

Page 1655: ...ED GRN RED RED BLU BLU BLK 4 RR LIGHT OFF 2 4 BLK YEL 1 3 BLU BLK BLK WHT RED BLK 1 2 GRN YEL BLU YEL BLU YEL 3 6 1 2 BLK YEL 10 5 4 2 1 RED BLK RED 3 5 2 1 WHT YEL BLK YEL No 3 7 5A IG2 BAT IGNITION...

Page 1656: ...dy ground with a jumper wire Go to step 4 Go to step 15 4 Disconnect the jumper wire 5 Disconnect the rear blower resistor 5P connector 6 Connect the No 1 terminal of the rear blower resistor 5P conne...

Page 1657: ...main relay 12 Turn the ignition switch OFF 13 Disconnect the rear heater A C main switch 10P connector 14 Check for continuity between the No 8 terminal of the rear heater A C main switch 10P connecto...

Page 1658: ...of the rear blower resistor Go to step 5 Replace the rear blower resistor 5 Check for continuity between the No 5 terminal of the rear blower resistor 5P connector and the No 2 terminal of the rear bl...

Page 1659: ...rear heater A C main switch 10P connector and the rear heater A C passenger s control panel 10P connector 11 Check for continuity between the No 3 terminal of the rear blower motor low relay 5P socket...

Page 1660: ...of the rear blower resistor Go to step 5 Replace the rear blower resistor 5 Check for continuity between the No 4 terminal of the rear blower resistor 5P connector and the No 2 terminal of the rear b...

Page 1661: ...he rear heater A C main switch 10P connector and the rear heater A C passenger s control panel 10P connector 11 Check for continuity between the No 3 terminal of the rear blower motor middle relay 5P...

Page 1662: ...o step 5 Replace the rear blower resistor 5 Measure the voltage between the No 1 terminal of the rear blower motor main relay 6P connector and body ground Go to step 6 Repair open in the wire between...

Page 1663: ...igh relay and test it see page 22 88 Go to step 11 Replace the rear blower motor high relay 11 Check for continuity between the No 2 terminal of the rear blower motor main relay 6P connector and the N...

Page 1664: ...C main switch 10P connector and the rear heater A C passenger s control panel 10P connector 17 Check for continuity between the No 4 terminal of the rear blower motor high relay 4P connector and the N...

Page 1665: ...40 and the rear heater A C passenger s control panel see page 21 141 Replace the switch as needed Repair open in the wire between the rear blower motor main relay and the rear heater A C main switch o...

Page 1666: ...ear mode control motor relay and test it see page 22 88 Go to step 12 Replace the rear mode control motor relay 12 Turn the ignition switch ON II 13 Measure the voltage between the No 5 terminal of th...

Page 1667: ...ode control motor relay 17 Disconnect the rear heater A C passenger s control panel 10P connector 18 Check for continuity between the No 6 terminal of the rear mode control motor 7P connector and body...

Page 1668: ...rear heater A C main switch and the rear heater A C passenger s control panel Go to step 22 22 Check for continuity between the No 3 terminal of the rear mode control motor relay 5P socket and the No...

Page 1669: ...ger s control panel Go to step 24 24 Check for continuity between the No 1 terminal of the rear mode control motor relay 5P socket and the No 7 terminal of the rear heater A C main switch 10P connecto...

Page 1670: ...thly and stop If the rear mode control motor does not run when jumping the first terminal jump that terminal again after jumping the other terminals The rear mode control motor is OK if it runs when j...

Page 1671: ...SWITCH 1 Remove the center panel with the rear heater A C main switch see page 20 69 2 Remove the self tapping screws and the rear heater A C main switch A from the center panel B 3 Install the main...

Page 1672: ...5 6 1 Terminal Position 1 8 7 9 Cool Hot 1 Remove the rear heater A C passenger s control panel A from the headliner then disconnect the 10P connector B Be careful not to damage the switch or the head...

Page 1673: ...the connectors A from the rear blower motor and the rear blower resistor then remove the self tapping screws the mounting bolts and the rear blower unit B 3 Install the unit in the reverse order of r...

Page 1674: ...ely Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination 6 Remove the clip A then lifting the upper duct B up Disconnect the connector C from the rear mo...

Page 1675: ...self tapping screws and the clamp A then remove the bolts and the evaporator lines B together with the expansion valve C If necessary remove the expansion valve Use a second wrench to hold the other...

Page 1676: ...r line A 13 N m 1 3 kgf m 9 4 lbf ft Rear receiver line C to the rear receiver line B 13 N m 1 3 kgf m 9 4 lbf ft Rear receiver line C to the rear evaporator heater unit 13 N m 1 3 kgf m 9 4 lbf ft Re...

Page 1677: ......

Page 1678: ...ow color coding Related components are located in the steering column front console dashboard dashboard lower panel in the dashboard above the glove box in the front seats and around the floor Do not...

Page 1679: ...nit Input Test 22 127 Headlight Replacement 22 129 Headlight Adjustment 22 130 Taillight Replacement 22 132 High Mount Brake Light Replacement 22 133 License Plate Light Replacement 22 133 Component L...

Page 1680: ...r Unit Input Test 22 276 Transmitter Test 22 278 Transmitter Programming 22 278 Door Lock Actuator Test 22 279 Door Lock Knob Switch Test 22 281 Door Tailgate Key Cylinder Switch Test 22 283 Door Lock...

Page 1681: ...scription Qty 22 2 Body Electrical Special Tools 07XAA 0010200 Antenna Nut Wrench 1 07WAZ 001010A MPCS Service Connector 1 07LAJ PT3020A Test Harness 1 07TAZ 001020A Back Probe Adaptor 1 03 07 29 10 1...

Page 1682: ...belt tension Make sure the connectors are clean and have no loose wire terminals Make sure multiple cavity connectors are packed with dielectric grease except watertight connectors All connectors have...

Page 1683: ...cover faces down Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations Remove clips carefully don t damage their locks A Slip pliers A under the cli...

Page 1684: ...no wires are pinched under them When using electrical test equipment follow the manufacturer s instructions and those described in this manual If possible insert the probe of the tester from the wire...

Page 1685: ...t tests to check the diagnosis you made in step 2 Keep in mind that a logical simple procedure is the key to efficient troubleshooting Test for the most likely cause of failure first Try to make tests...

Page 1686: ...R CLUTCH RELAY ELD UNIT INTERMITTENT WIPER RELAY FAIL SAFE RELAY MULTI FUSE RELAY BOX A FAN CONTROL RELAY TCS RELAY SEAT HEATER RELAY 02 EXL model MULTI FUSE RELAY BOX B Wire colors YEL RED BRN BLK WH...

Page 1687: ...C COMPRESSOR CLUTCH RELAY ELD UNIT INTERMITTENT WIPER RELAY FAIL SAFE RELAY MULTI RELAY BOX FAN CONTROL RELAY TCS RELAY SEAT HEATER RELAY EXL UNDER HOOD SUBFUSE BOX Wire colors YEL RED BRN BLK WHT BL...

Page 1688: ...ION DISPLAY UNIT AUTOMATIC CLIMATE CONTROL UNIT NAVIGATION UNIT CLIMATE CONTROL PANEL AUDIO UNIT CLIMATE CONTROL UNIT or HEATER CONTROL PANEL AUDIO UNIT DAYTIME RUNNING LIGHTS CONTROL UNIT DVD UNIT co...

Page 1689: ...S UNDER DASH FUSE RELAY BOX INTERIOR LIGHTS RELAY TAILLIGHT RELAY DAYTIME RUNNING LIGHTS RELAY PCM ABS CONTROL UNIT or ABS TCS CONTROL UNIT LOW BEAM CUT RELAY Wire colors RED GRN RED YEL RED GRN and R...

Page 1690: ...KET RELAY REAR WINDOW DEFOGGER RELAY PASSENGER S MULTIPLEX CONTROL UNIT BLOWER MOTOR HIGH RELAY KEYLESS RECEIVER UNIT 99 01 and 03 04 models CRUISE CONTROL UNIT IMMOBILIZER RECEIVER UNIT KEYLESS RECEI...

Page 1691: ...TENT CONTROL UNIT 01 04 models FUEL FILL DOOR RELAY 99 01 models FUEL FILL DOOR RELAY 02 04 models Wire colors BLU YEL BRN YEL YEL BLU GRN YEL and BLK YEL Wire colors BRN YEL BLK YEL BLK and BLU BLK W...

Page 1692: ...22 13 Roof REAR CONTROLLER and SCREEN With rear entertainment system...

Page 1693: ...ont Passenger s Seat 22 14 Relay and Control Unit Locations Door and Seat MULTIPLEX CONTROL UNIT DOOR POWER WINDOW CONTROL UNIT 03 04 models OPDS UNIT 02 04 models FRONT PASSENGER S SEAT SEAT WEIGHT U...

Page 1694: ...G551 and G552 see page 22 48 Right side wire harness C451 C452 C505 C506 C581 C761 C582 C583 C584 C589 C861 G581 and G582 see page 22 52 Tailgate wire harness C554 C555 C601 through C603 see page 22...

Page 1695: ...onnector to Harness Index T1 T2 1 4 Right side of engine compartment Left side of engine compartment Under hood fuse relay box Starter motor Battery Battery positive terminal T3 3 Left side of engine...

Page 1696: ...22 17 1 2 BATTERY GROUND CABLE 3 4 5 6 ENGINE GROUND CABLE STARTER CABLE...

Page 1697: ...gnition coil No 3 9 3 Middle of engine compartment Ignition coil No 4 47 3 Middle of engine compartment Ignition coil No 5 44 3 Middle of engine compartment Ignition coil No 6 42 3 Middle of engine co...

Page 1698: ...GINE WIRE HARNESS 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 KNOCK SENSOR SUBHARNESS 2 21...

Page 1699: ...range switch 19 10 On transmission housing Vehicle speed sensor VSS 17 3 Left side of engine compartment VTEC pressure switch 54 2 Right side of engine compartment VTEC solenoid valve 56 1 Right side...

Page 1700: ...1 ENGINE WIRE HARNESS 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 KNOCK SENSOR SUBHARNESS...

Page 1701: ...using Idle air control IAC valve 20 3 Left side of engine compartment Ignition coil No 1 5 3 Middle of engine compartment Ignition coil No 2 7 3 Middle of engine compartment Ignition coil No 3 9 3 Mid...

Page 1702: ...20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 KNOCK SENSOR SUBHARNESS 2 21 ENGINE WIRE HARNESS...

Page 1703: ...ssion housing VTEC pressure switch 53 2 Right side of engine compartment VTEC solenoid valve 55 1 Right side of engine compartment C101 25 10 Left side of engine compartment Left engine compartment wi...

Page 1704: ...25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 KNOCK SENSOR SUBHARNESS 2 21 ENGINE WIRE HARNE...

Page 1705: ...16 2 Middle of engine compartment Rear window washer motor 25 2 Behind right side of front bumper Right headlight 21 3 Behind right headlight Right side marker and turn signal lights 28 3 Behind right...

Page 1706: ...UNDER HOOD FUSE RELAY BOX 11 ABS RELAY BOX 13 12 27 1 2 3 8 9 10 14 15 16 17 RIGHT ENGINE COMPARTMENT WIRE HARNESS 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 35 PASSENGER S UNDER DASH FUSE RELAY...

Page 1707: ...model Multi fuse relay box No 63 fuse see page 22 78 33 Left side of engine compartment 02 model Optional connector 21 1 Left side of engine compartment Seat heater relay 34 4 Left side of engine com...

Page 1708: ...UNDER DASH FUSE RELAY BOX 25 24 23 22 21 18 17 16 19 20 15 14 13 12 11 10 3 2 9 8 7 6 5 4 1 LEFT ENGINE COMPARTMENT WIRE HARNESS MULTI FUSE RELAY BOX A 26 27 28 29 30 31 32 33 MULTI FUSE RELAY BOX B...

Page 1709: ...RS left front sensor 19 2 Behind left side of front bumper TCS relay 26 4 Left side of engine compartment Test tachometer connector 3 2 Left side of engine compartment Windshield wiper intermittent re...

Page 1710: ...22 31 DRIVER S UNDER DASH FUSE RELAY BOX 25 24 23 21 18 17 16 19 20 15 14 13 12 11 10 3 2 9 8 7 6 5 4 1 LEFT ENGINE COMPARTMENT WIRE HARNESS 26 27 28 29 30 31 MULTI RELAY BOX...

Page 1711: ...h 20 8 Under left side of dash 01 04 models Rear window wiper washer switch 20 6 Under left side of dash 99 00 models Security option connector 12 3 Under left side of dash Shift lock solenoid 15 2 Un...

Page 1712: ...22 33 DASHBOARD WIRE HARNESS B 8 9 10 11 12 13 14 1 2 3 4 5 6 7 15 16 17 18 19 20 26 23 22 21 24 25 DRIVER S UNDER DASH FUSE RELAY BOX Continues to right branch...

Page 1713: ...under dash fuse relay box connector K see page 22 77 8 16 Behind right kick panel Power transistor 12 5 Under right side of dash Automatic climate control Recirculation control motor 16 7 Under right...

Page 1714: ...22 35 DASHBOARD WIRE HARNESS B PASSENGER S UNDER DASH FUSE RELAY BOX 8 9 10 11 12 13 14 1 2 3 4 5 6 7 15 16 17 18 19 20 Continues to left branch...

Page 1715: ...ge 22 77 5 16 Behind right kick panel Passenger s under dash fuse relay box connector K see page 22 77 6 16 Behind right kick panel Power transistor 10 5 Under right side of dash Recirculation control...

Page 1716: ...22 37 DASHBOARD WIRE HARNESS B PASSENGER S UNDER DASH FUSE RELAY BOX 18 17 16 15 14 13 12 11 10 9 8 7 6 5 1 2 3 4 Continues to left branch...

Page 1717: ...nector B see page 22 77 31 22 Behind right kick panel Passenger s under dash fuse relay box connector H see page 22 77 33 18 Behind right kick panel Passenger s under dash fuse relay box connector I s...

Page 1718: ...t side wire harness see page 22 48 C502 3 22 Behind left kick panel Left side wire harness see page 22 48 Power sliding door C503 7 3 Behind left kick panel SRS main harness see page 22 61 C504 35 2 U...

Page 1719: ...witch 13 10 Behind hazard warning switch In car temperature sensor 37 2 Under middle of dash Automatic climate control Interior lights switch 18 6 Behind instrument panel 02 model Interior lights swit...

Page 1720: ...NESS A PASSENGER S UNDER DASH FUSE RELAY BOX 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 7 8 6 5 4 3 2 37 38 39 DRIVER S UNDER DASH FUSE RELAY BOX 40 41 42 43...

Page 1721: ...Behind left kick panel SRS main harness 02 model see page 22 62 03 04 models see page 22 64 TCS C504 32 8 Under middle of dash PCM subharness see page 22 68 2 C504 32 3 Under middle of dash PCM subha...

Page 1722: ...HARNESS A PASSENGER S UNDER DASH FUSE RELAY BOX 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 7 8 6 5 4 3 2 37 38 39 DRIVER S UNDER DASH FUSE RELAY BOX 40 41 42...

Page 1723: ...age 22 76 6 22 Behind left kick panel Multiplex control unit passenger s connector B see page 22 76 24 22 Behind right kick panel Navigation display unit connector A 14 5 Behind navigation display Nav...

Page 1724: ...HARNESS A PASSENGER S UNDER DASH FUSE RELAY BOX 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 7 8 6 5 4 3 2 37 38 39 DRIVER S UNDER DASH FUSE RELAY BOX 40 41 42...

Page 1725: ...panel Left side wire harness see page 22 48 01 model C502 38 13 Behind left kick panel Left side wire harness see page 22 48 02 04 models C503 42 3 Behind left kick panel SRS main harness see page 22...

Page 1726: ...RE HARNESS A PASSENGER S UNDER DASH FUSE RELAY BOX 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 7 8 6 5 4 3 2 37 38 39 DRIVER S UNDER DASH FUSE RELAY BOX 40 41...

Page 1727: ...valve 45 2 Middle of floor Fuel fill door relay 19 5 Left quarter panel Fuel fill door switch 23 2 Left quarter panel Fuel tank pressure FTP sensor 46 3 Middle of floor Left power sliding door control...

Page 1728: ...1 30 29 28 27 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 LEFT SIDE WIRE HARNESS FUEL UNIT SUBHARNESS 1 2 3 4 5 6 7 DRIVER S UNDER DASH FUSE RELAY BOX 40 39 38 37 26 36 8 41 42 43 44 45 46 47 48...

Page 1729: ...arness see page 22 60 02 04 models C551 35 2 Behind left kick panel SRS main harness see page 22 61 C552 29 4 Under driver s seat Driver s power seat wire harness see page 22 72 99 01 models C552 29 1...

Page 1730: ...2 31 30 29 28 27 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 LEFT SIDE WIRE HARNESS FUEL UNIT SUBHARNESS 1 2 3 4 5 6 7 DRIVER S UNDER DASH FUSE RELAY BOX 40 39 38 37 26 36 8 41 42 43 44 45 46 47...

Page 1731: ...ght sliding door motor 3 2 Right C pillar Right sliding door handle switch 9 2 Right C pillar Right sliding door sensor 4 4 Right C pillar Right sliding door switch 8 1 Right C pillar Right taillight...

Page 1732: ...22 53 RIGHT SIDE WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 1733: ...panel Rear A C blower motor main relay 37 4 Right quarter panel Rear A C blower motor middle relay 35 4 Right quarter panel Rear A C mode control motor 33 7 Right quarter panel Rear A C mode control m...

Page 1734: ...22 55 RIGHT SIDE WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 33 35 36 37 38 39 40 41 cont d...

Page 1735: ...60 Rear Heater A C C582 7 3 C pillar Roof wire harness see page 22 60 Ecept 04 model C583 9 2 Under front passenger s seat SRS floor subharness 02 model see page 22 62 03 04 models see page 22 64 C584...

Page 1736: ...22 57 RIGHT SIDE WIRE HARNESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 33 35 36 37 38 39 40 41...

Page 1737: ...dow C554 6 14 Left quarter panel Left side wire harness see page 22 48 C554 6 16 Left quarter panel Left side wire harness see page 22 48 Security C555 7 2 Left quarter panel Left side wire harness se...

Page 1738: ...t back up light 9 3 Behind right inner taillight Right inner taillight 8 2 Behind right inner taillight Tailgate key cylinder switch 10 3 Right side of tailgate Tailgate knob switch 12 3 Middle of tai...

Page 1739: ...controller and screen 5 26 Middle of roof Rear heater A C passenger s control panel 7 10 Roof area Right front individual map light 16 3 Right side of roof area Right rear individual map light 2 3 Ri...

Page 1740: ...ehind left kick panel Front passenger s airbag assembly 2 2 Behind glove box Memory erase signal MES connector 7 2 Behind left kick panel SRS unit 4 18 Middle of floor C503 6 3 Behind left kick panel...

Page 1741: ...1 22 28 Under middle of dash SRS floor harness SRS unit connector A 2 8 Under middle of dash SRS unit connector B 3 18 Under middle of dash SRS unit connector C 4 18 Under middle of dash C851 22 28 Un...

Page 1742: ...22 63 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 7 8 6 5 4 3 2 SRS MAIN HARNESS SRS FLOOR HARNESS SRS FLOOR SUBHARNESS RIGHT SIDE WIRE HARNESS OPDS UNIT HARNESS LEFT SIDE WIRE HARNESS 1...

Page 1743: ...el Dashboard wire harness A see page 22 40 C551 26 2 Behind left kick panel Left side wire harness C581 7 2 Under right side of dash Right side wire harness C851 25 28 Under middle of dash SRS floor h...

Page 1744: ...SRS FLOOR SUBHARNESS RIGHT SIDE WIRE HARNESS OPDS UNIT HARNESS LEFT SIDE WIRE HARNESS 30 28 29 DRIVER S SEAT WIRE HARNESS EX EXL or SEAT POSITION SENSOR SUBHARNESS LX RIGHT SIDE WIRE HARNESS 1 or FRON...

Page 1745: ...ness 03 model C861 13 4 Under front passenger s seat Front passenger s seat wire harness see page 22 73 2 C861 13 4 Under front passenger s seat OPDS unit harness Front passenger s seat belt tensioner...

Page 1746: ...SRS FLOOR SUBHARNESS RIGHT SIDE WIRE HARNESS OPDS UNIT HARNESS LEFT SIDE WIRE HARNESS 30 28 29 DRIVER S SEAT WIRE HARNESS EX EXL or SEAT POSITION SENSOR SUBHARNESS LX RIGHT SIDE WIRE HARNESS 1 or FRON...

Page 1747: ...sh Dashboard wire harness A see page 22 38 99 01 models C504 2 8 Under middle of dash Dashboard wire harness A see page 22 40 02 model with TCS and 03 model C504 2 3 Under middle of dash Dashboard wir...

Page 1748: ...ad Connector or Terminal Ref Cavities Location Connects to Notes 22 69 IGNITION SWITCH LEAD DRIVER S UNDER DASH FUSE RELAY BOX 1 Driver s under dash fuse relay box connector M see page 22 76 1 6 Under...

Page 1749: ...w motor 16 4 Driver s door 99 02 models Driver s power window motor 16 2 Driver s door 03 04 models Driver s power window motor hall IC sensor 17 4 Driver s door 03 04 models Driver s under dash fuse...

Page 1750: ...or Passenger s window switch 3 6 Passenger s door Passenger s under dash fuse relay box connector B see page 22 77 15 4 Behind right kick panel Seat heater Passenger s under dash fuse relay box connec...

Page 1751: ...4 models Driver s seat position sensor 5 2 Under driver s seat 03 04 models Power seat front up down motor 2 2 Under driver s seat Power seat rear up down motor 1 2 Under driver s seat Power seat recl...

Page 1752: ...s 22 73 4 3 2 1 FRONT PASSENGER S SEAT WIRE HARNESS Front passenger s seat belt switch 3 3 Under front passenger s seat Front passenger s seat heater 1 5 Under front passenger s seat C589 4 10 Under f...

Page 1753: ...Harnesses Connector to Harness Index cont d 1 2 4 A T SUBHARNESS 3 A T fluid temperature sensor 2 2 On transmission housing 3rd clutch pressure switch 4 1 On transmission housing C151 1 8 On transmiss...

Page 1754: ...utch relay 3 4 B 14 7 Right engine compartment wire harness see page 22 26 Blower motor relay 11 4 C 13 3 Right engine compartment wire harness see page 22 26 Condenser fan relay 1 4 D 12 16 Right eng...

Page 1755: ...70 G 8 18 Driver s door wire harness see page 22 70 H 5 6 Driver s door wire harness see page 22 70 I 13 18 Dashboard wire harness A see page 22 38 J 12 3 Dashboard wire harness B see page 22 32 K 14...

Page 1756: ...26 Diode 1 2 for A C Diode 2 Not used Diode 3 Not used E 8 2 Front passenger s door wire harness see page 22 71 F 7 20 Front passenger s door wire harness see page 22 71 G 6 3 Front passenger s door w...

Page 1757: ...se Relay Boxes Connector to Fuse Relay Box Index cont d 60 61 1 2 MULTI FUSE RELAY BOX A 3 62 63 MULTI FUSE RELAY BOX B Intermittent wiper relay 1 5 Left engine compartment wire harness see page 22 28...

Page 1758: ...Under hood Sub fuse Box 03 04 models Socket Ref Terminal Connects to 22 79 1 T5 1 Left engine compartment wire harness see page 22 30...

Page 1759: ...e light Horns Ignition key light Key interlock solenoid Driver s multiplex control unit PCM Trailer lighting connector 48 20A WHT GRN ABS pump motor relay ABS modulator unit ABS TCS control unit ABS T...

Page 1760: ...noid valve Engine mount control solenoid valve PCM Primary and secondary heated oxygen sensors Vehicle speed sensor VSS with navigation system 7 10A YEL GRN Rear window wiper motor Rear window washer...

Page 1761: ...n switch light Gauge assembly Hazard warning switch light Heater control panel Interior lights switch light Driver s multiplex control unit Power sliding door switch light Rear A C fan switch light Ta...

Page 1762: ...model Fuse Number Amps Wire Color Component s or Circuit s Protected 22 83 60 61 62 63 60 40A RED Rear A C blower motor 61 30A WHT BLK Left power sliding door control unit 62 20A WHT GRN Seat heater...

Page 1763: ...2 73 74 75 76 77 78 71 20A WHT BLU Audio unit DVD unit Rear controller and screen 72 Not used 73 Not used 74 Not used 75 Not used 76 Not used 77 Not used 78 20A WHT GRN Seat heater EXL 79 20A WHT RED...

Page 1764: ...main switch Data link connector DLC Front accessory power socket Interior lights switch Driver s multiplex control unit Navigation display unit Navigation unit Power mirror switch Power sliding door s...

Page 1765: ...relay box A or the passenger s fuse relay box B 6 Remove the mounting bolt release the clips C at the middle on both sides of the box and pull the fuse relay box away from the body 7 Disconnect the d...

Page 1766: ...go to step 3 3 Check the indicator EYE If the EYE indicates the battery is charged go to step 4 If the EYE indicates a low charge go to step 7 4 Apply a 300 amp load for 15 seconds to remove the surfa...

Page 1767: ...ut relay Taillight relay TCS relay ABS pump motor relay Normally open type B Blower motor relay Blower motor high relay Rear A C blower high relay Rear window defogger relay Rear A C blower main relay...

Page 1768: ...gger relay 22 89 1 2 3 4 3 4 2 1 1 2 3 4 3 4 2 1 1 2 3 4 1 2 3 4 Check for continuity between the terminals There should be continuity between the No 1 and No 3 terminals when power and ground are con...

Page 1769: ...No 2 terminals when power and ground are connected to the No 3 and No 5 terminals There should be continuity between the No 2 and No 4 terminals when power is disconnected Check for continuity betwee...

Page 1770: ...then write down the frequencies for the radio s preset buttons 2 Disconnect the battery negative cable 3 Remove the dashboard lower cover see page 20 69 4 Disconnect the 6P connector from the driver...

Page 1771: ...system then write down the frequencies for the radio s preset buttons 2 Disconnect the battery negative cable 3 Remove the steering column covers see page 17 25 4 Insert the ignition key and turn it...

Page 1772: ...SWITCH GAUGE ASSEMBLY BRAKE FLUID LEVEL SWITCH ENGINE OIL PRESSURE SWITCH COOLANT TEMPERATURE GAUGE SENDING UNIT cont d page 11 139 page 19 11 Replacement page 22 100 Bulb Locations page 22 95 Resetti...

Page 1773: ...OSITION INDICATOR FUEL GAUGE SAFETY INDICATOR CONNECTOR B CONNECTOR A CONNECTOR C A7 A14 A1 A6 C1 C7 C8 C16 B1 B10 B11 B22 MAINTENANCE REQUIRED INDICATOR COOLANT TEMPERATURE GAUGE 99 00 models 01 mode...

Page 1774: ...HT 1 4 W MAINTENANCE REQUIRED INDICATOR REMINDER LIGHT 1 4 W LOW ENGINE OIL PRESSURE INDICATOR LIGHT 1 4 W GAUGE LIGHT 3 4 W LCD BACK LIGHT 1 4 W GAUGE LIGHT 3 4 W LOW FUEL INDICATOR LIGHT 1 4 W 99 01...

Page 1775: ...SEMBLY B11 B21 A13 YEL WHT YEL PASSENGER S UNDER DASH FUSE RELAY BOX DRIVER S UNDER DASH FUSE RELAY BOX HIGH BEAM INDICATOR LIGHT 1 4W IMMOBILIZER INDICATOR LIGHT 1 4W SECURITY INDICATOR LIGHT LED CHA...

Page 1776: ...S INDICATOR LIGHT 1 4W LOW ENGINE OIL PRESSURE INDICATOR LIGHT 1 4W CRUISE INDICATOR LIGHT 2 0W SLIDING DOOR INDICATOR LIGHT 1 4W CRUISE CONTROL UNIT DRIVER S MULTIPLEX CONTROL UNIT ENGINE OIL PRESSUR...

Page 1777: ...CONTROL UNIT SIDE AIRBAG CUTOFF INDICATOR LIGHT 1 4W SRS INDICATOR CIRCUIT ABS INDICATOR CIRCUIT SRS INDICATOR LIGHT 1 4W ABS INDICATOR LIGHT 1 4W LEFT TURN SIGNAL INDICATOR LIGHT 1 4W RIGHT TURN SIG...

Page 1778: ...CM BLU BLU B1 BLU WHT B2 TEST TACHOMETER CONNECTOR COOLANT TEMPERATURE GAUGE FUEL GAUGE LOW FUEL INDICATOR LIGHT 1 4W or LED TACHO METER SPEEDO METER FUEL GAUGE DRIVE CIRCUIT TACHOMETER DRIVE CIRCUIT...

Page 1779: ...umn cover 3 Disconnect the connectors D and remove the gauge assembly 4 Install in the reverse order of removal Press the select switch and reset switch at the same time turn the ignition switch ON II...

Page 1780: ...he gauge assembly on a shop rag 4 Put the vehicle in neutral position with the ignition switch ON II 5 Slowly rotate over 3 mph 2 km h one wheel with the other wheel blocked Substitute a known good ga...

Page 1781: ...the cruise control unit On EX and EXL models disconnect the left and right power sliding door control units 13 Check for continuity between PCM connector A No 9 terminal or PCM connector E No 26 termi...

Page 1782: ...OR SWITCH RIGHT REAR DOOR SWITCH TAILGATE LATCH SWITCH BRAKE LIGHT FAILURE SENSOR LEFT REAR DOOR SWITCH DRIVER S DOOR SWITCH BRAKE PEDAL POSITION SWITCH SAFETY INDICATOR Test page 22 148 Test page 22...

Page 1783: ...sembly G552 BLK BLK YEL WHT WHT YEL UNDER HOOD FUSE RELAY BOX BATTERY G503 BLK B11 GRN ORN GRN ORN YEL DRIVER S UNDER DASH FUSE RELAY BOX CEILING LIGHT DRIVER S MULTIPLEX CONTROL UNIT PASSENGER S MULT...

Page 1784: ...LK 5 YEL WHT BLK WHT BLK WHT BLK WHT YEL BRAKE LIGHT FAILURE SENSOR BRAKE PEDAL POSITION SWITCH LEFT BRAKE LIGHT 21W RIGHT BRAKE LIGHT 21W HIGH MOUNT BRAKE LIGHT 18W ABS CONTROL UNIT ABS TCS CONTROL U...

Page 1785: ...embly see page 22 100 2 Disconnect the 14P connector A and 22P connector B from the gauge assembly 3 Inspect the connector and socket terminals to be sure they are all making good contact If the termi...

Page 1786: ...y box An open in the wire B8 WHT BLU Engine running Check for voltage to ground There should be battery voltage Faulty charging system An open in the wire A7 GRN Front passenger s door open Check for...

Page 1787: ...s on check for a short to ground between the No 11 terminal of the gauge assembly connector A 14P and the No 4 terminal of the failure sensor a faulty safety indicator circuit printed circuit board in...

Page 1788: ...1 A18 A13 B11 A1 WHT BLK No 9 10A BATTERY IGNITION SWITCH No 42 50A UNDER HOOD FUSE RELAY BOX IG1 BAT No 41 120A WHT BLK YEL 20A No 47 DRIVER S UNDER DASH FUSE RELAY BOX IGNITION KEY LIGHT LED PASSEN...

Page 1789: ...system If all the input tests prove OK go to step 5 A24 Fuse relay box socket Ignition switch ON II Check for voltage to ground There should be battery voltage Blown No 9 10A fuse in the driver s unde...

Page 1790: ...unbuckled Check for voltage to ground There should be 1 V or less Faulty driver s seat belt switch Poor ground G551 An open in the wire Ignition switch ON II driver s seat belt buckled Check for volt...

Page 1791: ...LLIGHT LOW BEAM CUT RELAY Replacement page 22 129 Replacement page 22 129 Wire colors RED ORN WHT RED RED WHT and ORN BLK Canada Wire colors RED ORN RED WHT RED GRN and RED YEL With automatic light of...

Page 1792: ...HTS CONTROL UNIT DASH LIGHTS BRIGHTNESS CONTROLLER HEADLIGHT RELAY 2 Left HEADLIGHT RELAY 1 Right UNDER HOOD FUSE RELAY BOX Canada Bulb Locations page 22 95 Bulb Locations page 22 95 Test Replacement...

Page 1793: ...HT RED YEL RED YEL UNDER HOOD FUSE RELAY BOX YEL BLU RED 6 OFF DIMMER LOW HIGH PASSING RED GRN RED YEL 15A No 43 No 45 15A No 41 120A BATTERY HEADLIGHT RELAY 2 HEADLIGHT RELAY 1 HIGH BEAM INDICATOR LI...

Page 1794: ...LIGHT UNDER HOOD FUSE RELAY BOX YEL BLU RED 6 OFF DIMMER LOW HIGH PASSING RED GRN RIGHT LEFT HEADLIGHT RED YEL 15A No 43 No 45 15A No 41 120A BATTERY HEADLIGHT RELAY 2 HEADLIGHT RELAY 1 HIGH BEAM INDI...

Page 1795: ...13 GRN RED 6 GRN WHT 4 5 DAYTIME RUNNING LIGHTS CONTROL UNIT 12 YEL RED RED BLU 2 YEL GRN 40A No 55 No 6 10A No 5 7 5A YEL IGNITION SWITCH IG2 BAT WHT G301 BLK BLK G401 No 41 120A BATTERY DRL INDICAT...

Page 1796: ...0A WHT RED WHT RED RED YEL YEL BLU RED 6 COMBINATION LIGHT SWITCH OFF DIMMER LOW HIGH PASSING RED GRN RED YEL 15A No 43 No 45 15A HEADLIGHT RELAY 2 HEADLIGHT RELAY 1 PASSENGER S MULTIPLEX CONTROL UNIT...

Page 1797: ...RED 6 GRN WHT 4 5 DAYTIME RUNNING LIGHTS CONTROL UNIT 12 YEL RED RED BLU 2 YEL GRN 40A No 55 No 6 10A No 5 7 5A YEL IG2 BAT WHT G301 BLK BLK G401 No 41 120A UNDER HOOD FUSE RELAY BOX BATTERY IGNITION...

Page 1798: ...YEL BLU RED 6 COMBINATION LIGHT SWITCH OFF DIMMER LOW HIGH PASSING RED GRN RED YEL 15A No 43 No 45 15A HEADLIGHT RELAY 2 HEADLIGHT RELAY 1 PASSENGER S MULTIPLEX CONTROL UNIT PASSENGER S UNDER DASH FU...

Page 1799: ...G101 BLK Closed In position GRN BLK WHT BLK YEL IG1 BAT IGNITION SWITCH WHT UNDER HOOD FUSE RELAY BOX No 42 50A No 41 120A BATTERY DRIVER S UNDER DASH FUSE RELAY BOX REVERSE RELAY LEFT BACK UP LIGHT...

Page 1800: ...YEL IG1 BAT IGNITION SWITCH WHT UNDER HOOD FUSE RELAY BOX No 47 20A No 42 50A No 41 120A BATTERY BRAKE PEDAL POSITION SWITCH Closed Pedal pressed DRIVER S UNDER DASH FUSE RELAY BOX SAFETY INDICATOR D...

Page 1801: ...RED A16 A12 A24 10A No 9 BLK YEL IG1 BAT IGNITION SWITCH WHT YEL No 42 50A DRIVER S MULTIPLEX CONTROL UNIT A13 BRN GRN ORN BLU WHT 3 1 BLK G401 UNDER HOOD FUSE RELAY BOX No 54 40A No 41 120A BATTERY...

Page 1802: ...connect the 14P connector A from the combination light switch B 4 Remove the two screws then pull out the combination light switch 5 Inspect the connector terminals to be sure they are all making good...

Page 1803: ...IVER S UNDER DASH FUSE RELAY BOX CONNECTOR Q BLU WHT RED YEL 1 Before testing the exterior lights control functions troubleshoot the multiplex control system see page 22 244 2 Remove the driver s mult...

Page 1804: ...nd There should be 1 V or less Faulty driver s door switch An open in the wire Driver s door closed Check for voltage to ground There should be 5 V or more Faulty driver s door switch A short to groun...

Page 1805: ...ect the cause then recheck the system If all the input tests prove OK go to step 9 A17 BLK RED Driver s door lock knob locked Check for voltage to ground There should be 5 V or more Faulty driver s do...

Page 1806: ...the glove box see page 20 71 2 Disconnect the 14P connector A from the daytime running lights control unit B 3 Inspect the all connector and socket terminals to be sure they are all making good conta...

Page 1807: ...for continuity to ground There should be continuity Poor ground G401 An open in the wire 7 6 GRN WHT Parking brake pedal pressed Check for continuity to ground There should be continuity Faulty parkin...

Page 1808: ...any attaching hardware immediately after they have been turned off 1 Remove the front bumper see page 20 128 2 Disconnect the connectors A from the headlight 3 Remove the four mounting bolts then remo...

Page 1809: ...off Park the vehicle on level surface Make sure the tire pressures are correct The driver or someone who weighs the same should sit in the driver s seat 1 Clean the outer lens so that you can see the...

Page 1810: ...elow headlight height B The width of the refracting points C should be the same as the width of the headlight central points D E 7 If necessary adjust the headlights to local requirements by turning t...

Page 1811: ...items Inspect the gasket replace it if it is distorted or stays compressed After installing the taillight run water over it to make sure it does not leak 1 Remove the tailgate trim panel see page 20...

Page 1812: ...nse Plate Light Replacement B A B A C 1 Remove the cover A then remove the screw B from the high mount brake light 2 Disconnect the 2P connector from the high mount brake light 1 Pull the license plat...

Page 1813: ...N SIGNAL INDICATOR LIGHTS HAZARD WARNING SWITCH TURN SIGNAL HAZARD RELAY DRIVER S UNDER DASH FUSE RELAY BOX HAZARD WARNING SWITCH Test page 22 123 In the gauge assembly Bulb Location page 22 95 Withou...

Page 1814: ...D FUSE RELAY BOX WHT IGNITION SWITCH IG1 BAT WHT GRN BLK YEL RED BLK ON L R OFF GRN YEL GRN RED GRN RED GRN WHT RED L R GRN BLU GRN YEL GRN BLU RIGHT TURN SIGNAL LIGHTS BLK BLK BLK BLK BLK G401 DRIVER...

Page 1815: ...aulty replace it 1 Under all conditions Check for continuity to ground There should be continuity Poor ground G401 An open in the wire 2 Ignition switch ON II Check for voltage to ground There should...

Page 1816: ...tch from behind the center panel C 4 Check for continuity between the terminals in each switch position according to the table 5 If the continuity is not as specified replace the bulb D or the switch...

Page 1817: ...LEFT SLIDING DOOR SWITCH LEFT REAR INDIVIDUAL MAP LIGHTS RIGHT SLIDING DOOR SWITCH INTERIOR LIGHTS SWITCH IGNITION KEY LIGHT Test page 22 150 Test page 22 145 Wire colors BLK BLU WHT BLU LT GRN BLK T...

Page 1818: ...UNDER DASH FUSE RELAY BOX DRIVER S UNDER DASH FUSE RELAY BOX INTERIOR LIGHTS RELAY INTERIOR LIGHTS SWITCH IGNITION KEY LIGHT LED Fuse relay box socket DOOR MULTIPLEX CONTROL UNIT DRIVER S MULTIPLEX C...

Page 1819: ...CONNECTOR B RED GRN 1 Before testing the entry light control functions troubleshoot the multiplex control system see page 22 244 2 Remove the driver s multiplex control unit from the driver s under da...

Page 1820: ...dash fuse relay box Faulty driver s fuse relay box 5 Reconnect the driver s multiplex control unit to the fuse relay box and perform the following input tests at the appropriate connectors on the bac...

Page 1821: ...S UNDER DASH FUSE RELAY BOX CONNECTOR A 6 Remove the passenger s multiplex control unit from the passenger s under dash fuse relay box and disconnect its connector 7 Inspect the connector and socket...

Page 1822: ...se relay box Faulty interior lights relay Faulty interior lights switch Faulty ceiling light bulb Poor ground G401 An open in the wire 9 Reconnect the passenger s multiplex control unit to the fuse re...

Page 1823: ...nd correct the cause then recheck the system If the input test proves OK go to step 13 A17 BLK RED Driver s door lock knob locked Check for voltage to ground There should be 5 V or more Faulty driver...

Page 1824: ...er and lower covers see page 17 25 2 Disconnect the 7P connector NOTE Lock tab A points down when installed 3 Check for continuity between terminals No 1 and No 3 There should be continuity with the k...

Page 1825: ...FRONT INDIVIDUAL MAP LIGHTS CARGO AREA LIGHT INTERIOR LIGHTS SWITCH CENTER POCKET LIGHT Replacement page 22 152 Test page 22 150 Wire colors BLK BLU WHT BLU LT GRN BLK Test page 22 88 Test page 22 150...

Page 1826: ...N WHT WHT BLU WHT BLU GRN WHT BLK BLU BLK BLU GRN WHT WHT BLU 2 LX model EX and EXL models 1 WHT BLU No 11 10A G582 YEL UNDER HOOD FUSE RELAY BOX No 54 40A No 41 120A BATTERY PASSENGER S UNDER DASH FU...

Page 1827: ...s in each switch position according to the table 5 If the continuity is not as specified replace the bulb C or the switch 1 Open the tailgate 2 Remove the tailgate lower trim see page 20 61 3 Disconne...

Page 1828: ...refully pry off the lens A with a small screwdriver 2 Remove the four mounting screws B 3 Disconnect the 3P connector C from the housing D 4 Check for continuity between the terminals in each switch p...

Page 1829: ...OFF ON 1 Carefully pry off the lens A with a small screwdriver 2 Remove the mounting screw B 3 Disconnect the 3P connector C from the housing D 4 Check for continuity between the terminals in each sw...

Page 1830: ...h OFF 2 Carefully pry off the lens A with a small screwdriver 3 Remove the two mounting screws B and the housing C 4 Disconnect the 3P connector D from the housing 5 Check for continuity between the t...

Page 1831: ...f the lens A with a small screwdriver 1 Remove the center pocket see page 20 67 2 Disconnect the 2P connector from the center pocket light 3 Check for continuity between the No 1 and No 2 terminals Wi...

Page 1832: ...13 7 5A A12 HEATER CONTROL PANEL LIGHT HAZARD WARNING SWITCH LIGHT CRUISE MAIN SWITCH LIGHT CLOCK BLK G401 RED RED RED WHT RED A20 B4 B3 A14 A6 B5 B10 B4 B22 GAUGE ASSEMBLY RED BLK RED WHT 3 4Wx3 3 0W...

Page 1833: ...Y BOX CONNECTOR O 1 Before testing the dash lights brightness control functions troubleshoot the multiplex control system see page 22 244 2 Remove the driver s multiplex control unit from the driver s...

Page 1834: ...between the B3 and B4 terminals There should be 0 20 k at all times Faulty dash lights brightness controller An open in the wire 5 Reconnect the driver s multiplex control unit to the fuse relay box a...

Page 1835: ...st see page 22 154 2 Remove the gauge assembly A see page 22 100 3 Disconnect the 22P connector B 4 At the gauge assembly measure resistance between the B4 and B5 terminals while rotating the adjustin...

Page 1836: ...SPEAKERS RIGHT TWEETER MAST ANNTENNA LEFT TWEETER AUDIO UNIT Replacement page 22 161 Replacement page 22 161 Test page 22 160 Replacement page 22 161 Replacement page 22 161 Replacement page 22 162 R...

Page 1837: ...RED YEL BLK GRY BLK BLU GRN RED GRN BRN BLK BATTERY No 42 50A UNDER HOOD FUSE RELAY BOX No 54 40A WHT WHT BLK BAT ACC RED BLK No 8 7 5A WHT RED GRY WHT BLU YEL RED YEL BRN WHT BRN BLK RED GRN BLU GRN...

Page 1838: ...ashboard and related parts 1 Make sure you have the anti theft codes for the radio and the navigation system then write down the frequencies for the radio s preset buttons 2 Remove the center panel se...

Page 1839: ...hts on signal 10 WHT BLU Constant power 11 ORN Navigation unit 12 BLU GRN Navigation unit 13 ORN BLU Navigation unit 14 WHT BLK Navigation unit 15 BRN WHT Right rear speaker 16 GRY WHT Left rear speak...

Page 1840: ...20 7 2 Remove the speaker cover A 3 Remove the three screws then disconnect the 2P connector B from the speaker C Carefully pry the tweeter A out of the dashboard then disconnect the 2P connector B f...

Page 1841: ...B A Antenna nut wrench 07XAA 0010200 1 Remove the antenna mast A 2 Remove the antenna nut B spacer C and bushing D 3 Remove the right inner fender see page 20 149 4 Remove the antenna housing bracket...

Page 1842: ...42 50A 40A No 54 No 41 120A BATTERY UNDER HOOD FUSE RELAY BOX IGNITION SWITCH DRIVER S UNDER DASH FUSE RELAY BOX ACCESSORY POWER SOCKET RELAY PASSENGER S UNDER DASH FUSE RELAY BOX FRONT ACCESSORY POW...

Page 1843: ...ecessary and recheck the system If the terminals look OK go to step 4 4 Turn the ignition switch to ACC I 5 Check for voltage between the No 1 and No 2 terminals There should be battery voltage If the...

Page 1844: ...ry and recheck the system If the terminals look OK go to step 4 4 Turn the ignition switch to ACC I 5 Check for voltage between the No 1 and No 2 terminals There should be battery voltage If there is...

Page 1845: ...WINDOW DEFOGGER SWITCH CLIMATE CONTROL UNIT CLIMATE CONTROL UNIT REAR WINDOW DEFOGGER SWITCH Function Test page 22 168 Defogger Wire Repair page 22 168 The switch is built into the climate control uni...

Page 1846: ...BRN YEL BLK GRN IG2 No 53 30A BATTERY No 41 120A No 42 50A UNDER HOOD FUSE RELAY BOX WHT BAT IGNITION SWITCH WHT GRN DRIVER S UNDER DASH FUSE RELAY BOX REAR WINDOW DEFOGGER RELAY PASSENGER S UNDER DA...

Page 1847: ...ulty rear window defogger relay If there is battery voltage go to step 2 2 Check for continuity between the negative terminal Driver s side B and body ground If there is no continuity check for an ope...

Page 1848: ...mmed properly see the owner s manual or call Homelink at 800 355 3515 On the internet go to www homelink com If the front individual map lights do not come on check for these problems a blown No 11 10...

Page 1849: ...13 BLK YEL IG1 BAT YEL WHT UNDER HOOD FUSE RELAY BOX No 54 40A No 42 50A No 41 120A BATTERY IGNITION SWITCH DRIVER S UNDER DASH FUSE RELAY BOX PASSENGER S UNDER DASH FUSE RELAY BOX COMBINATION LIGHT...

Page 1850: ...nnectors see page 20 69 2 Remove the three screws from the clock A 3 Separate the clock and hazard warning switch B 1 YEL IG1 main clock power supply 2 WHT YEL Constant power 3 RED BLK Lights on signa...

Page 1851: ...22 172 Horns Component Location Index HORN RELAY UNDER HOOD FUSE RELAY BOX HORN SWITCH CABLE REEL HORNS Test page 22 88 Test page 22 174 page 23 376 Test and Replacement page 22 173...

Page 1852: ...B A B A 1 Remove the front bumper see page 20 128 2 Disconnect the 1P connector B and remove the horn A 3 Test the horn by connecting battery power to the terminal A and grounding the bracket B The h...

Page 1853: ...when the horn switch is pushed There should be no continuity when the horn switch is released If both continuity checks are OK the horn switch is OK If neither check is OK go to step 5 5 Remove the dr...

Page 1854: ...nent Location Index FRONT UP DOWN MOTOR SLIDE MOTOR REAR UP DOWN MOTOR RECLINE MOTOR ADJUSTMENT SWITCH Motor Test page 22 178 Motor Test page 22 178 Motor Test page 22 178 Motor Test page 22 178 Test...

Page 1855: ...L GRN RED YEL BLU GRN YEL B6 B2 UNDER HOOD FUSE RELAY BOX POWER SEAT ADJUSTMENT SWITCH RED BLU BLK BLK YEL GRN GRN YEL BLU YEL RED G551 G551 UP DOWN UP DOWN No 55 40A No 41 120A BATTERY PASSENGER S UN...

Page 1856: ...switch cover A from the driver s seat by removing the three screws and pulling off the adjustment switch knobs B 2 Disconnect the 6P connectors C from the adjustment switch D then remove the switch fr...

Page 1857: ...tion 1 Remove the driver s seat see page 20 81 2 Remove the adjustment switch cover A by removing the three screws 3 Disconnect the 6P connectors from the adjustment switch B 4 Test the motor When the...

Page 1858: ...Power Mirrors Component Location Index POWER MIRRORS POWER MIRROR SWITCH Function Test page 22 182 Actuator Test page 22 184 Replacement page 20 33 Mirror Actuator Replacement page 22 185 Test page 2...

Page 1859: ...2 10 9 8 7 RIGHT LEFT LEFT RIGHT No 4 7 5A YEL IGNITION SWITCH IG2 BAT BLU WHT BLU GRN YEL WHT BLU ORN BLU WHT BLU WHT UNDER HOOD FUSE RELAY BOX LEFT MIRROR RIGHT MIRROR 2 2 1 3 3 1 UP RIGHT LEFT DOW...

Page 1860: ...U ORN BLU WHT BLU WHT LEFT MIRROR RIGHT MIRROR 5 5 4 6 6 4 UP RIGHT LEFT DOWN DOWN LEFT RIGHT UP LT GRN G501 POWER MIRROR SWITCH 4 1 YEL BLK DOWN RIGHT LEFT UP 2 10 9 8 7 RIGHT LEFT LEFT RIGHT No 4 7...

Page 1861: ...left mirror should tilt down or swing left with the ignition switch ON II If the mirror does not tilt down or does not swing left check for an open in the BLU WHT or BLU ORN wire between the left mir...

Page 1862: ...UP DOWN LEFT RIGHT R 1 2 4 7 8 9 10 Terminal Position ON OFF 3 6 1 Remove the dashboard lower cover see page 20 69 2 Disconnect the 10P connector A from the power mirror switch B 3 Check for continui...

Page 1863: ...panel see page 20 7 2 Disconnect the 3P or 6P connector A from the power mirror B 3 Check actuator operation by connecting power and ground according to the table 4 If the mirror fails to work proper...

Page 1864: ...2 Disconnect the 3P or 6P connector from the mirror 3 Cut the wire harness A with a wire cutter 4 Remove the seat base B 5 Remove the mirror holder A see page 20 35 6 Pry off the holder A from the hou...

Page 1865: ...GRN BLU YEL GRN YEL WHT Canada 9 Install in the reverse of removal Replace the mirror and three screws with new one 10 Insert the terminals into the connector in the original arrangement as shown bel...

Page 1866: ...OTOR CLOSE RELAY POWER WINDOW CONTROL UNIT Test page 22 88 Resetting page 22 200 Replacement page 22 215 Test page 22 212 Test page 22 214 In the passenger s multiplex control unit Input Test page 22...

Page 1867: ...HT BLU No 51 40A No 13 7 5A BATTERY No 54 40A UNDER HOOD FUSE RELAY BOX No 41 120A YEL PASSENGER S MULTIPLEX CONTROL UNIT POWER WINDOW RELAY LEFT REAR WINDOW SWITCH FRONT PASSENGER S WINDOW SWITCH RIG...

Page 1868: ...BLU A11 A19 A12 BLK BLK G551 BLK BLK PULSER A15 WHT RED B2 B1 A1 POWER WINDOW MASTER SWITCH In the DOOR MULTIPLEX CONTROL UNIT DRIVER S SWITCH FRONT PASSENGER S LEFT REAR RIGHT REAR MAIN SWITCH DRIVE...

Page 1869: ...CONTROL UNIT GRN ORN WHT YEL A2 1 2 GRN YEL GRN RED WHT YEL WHT RED BLU YEL A19 BRN PNK B1 A7 BLU A12 A14 BLK G401 A16 DOOR MULTIPLEX CONTROL UNIT No 13 7 5A PASSENGER S FUSE No 7 7 5A PASSENGER S FU...

Page 1870: ...U UP DOWN BLU BLK 3 6 5 WHT RED BLU YEL BLU WHT 2 1 2 1 4 1 2 WHT BLK BLU YEL A7 A6 BLU WHT YEL GRN A15 A12 BLK B9 RED YEL RED BLU WHT RED A24 A8 G581 No 13 7 5A PASSENGER S FUSE No 16 7 5A PASSENGER...

Page 1871: ...16 20A No 8 No 7 7 5A GRN WHT G581 BLK WHT BLU No 51 40A No 13 7 5A BATTERY No 54 40A UNDER HOOD FUSE RELAY BOX No 41 120A YEL PASSENGER S UNDER DASH FUSE RELAY BOX PASSENGER S MULTIPLEX CONTROL UNIT...

Page 1872: ...X CONTROL UNIT WHT YEL DN DOWN RIGHT REAR DN UP UP DN LEFT REAR RIGHT FRONT DN UP 4 3 1 2 RED YEL A10 DN AUTO UP RED BLU A11 A4 A12 BLK RED G551 BLK PULSER A15 WHT RED B2 B1 PASSENGER S SWITCH MAIN SW...

Page 1873: ...A17 A DRIVER S MULTIPLEX CONTROL UNIT A2 A7 BRN A19 A14 BLK G401 A16 DOOR MULTIPLEX CONTROL UNIT No 7 7 5A PASSENGER S FUSE PASSENGER S MULTIPLEX CONTROL UNIT Key off timer circuit Fuse relay box sock...

Page 1874: ...RED WHT RED WHT RED OPEN CLOSE 1 2 WHT BLK BLU YEL A6 A7 BLU RED YEL RED BLU WHT RED DOWN BLU BLK 3 5 6 1 5 3 WHT RED BLU YEL BLU WHT 2 1 1 2 4 6 UP PASSENGER S MULTIPLEX CONTROL UNIT Key off timer ci...

Page 1875: ...20A No 8 No 7 7 5A GRN WHT G581 BLK WHT BLU No 51 40A No 13 7 5A BATTERY No 54 40A UNDER HOOD FUSE RELAY BOX No 41 120A YEL PASSENGER S UNDER DASH FUSE RELAY BOX POWER WINDOW RELAY LEFT REAR WINDOW SW...

Page 1876: ...RN YEL B4 B3 GRN RED YEL WHT B1 B2 YEL BLU UP DOWN WHT RED B2 DN DOWN UP AUTO BLU GRN 7 4 14 A14 BLU ORN A4 11 YEL GRN BLK WHT 13 A11 A10 15 RED GRN BLK B1 BLK A20 BLK G401 A12 BLK 8 GRN WHT GRN WHT 1...

Page 1877: ...A17 DRIVER S MULTIPLEX CONTROL UNIT A2 A7 BRN A19 A14 BLK G401 A16 DOOR MULTIPLEX CONTROL UNIT PASSENGER S MULTIPLEX CONTROL UNIT Key off timer circuit No 7 7 5A PASSENGER S FUSE Fuse relay box socket...

Page 1878: ...WHT RED WHT RED OPEN CLOSE 1 2 WHT BLK BLU YEL A6 A7 BLU RED YEL RED BLU WHT RED DOWN BLU BLK 5 1 3 WHT RED BLU YEL BLU WHT 2 1 2 6 UP PASSENGER S MULTIPLEX CONTROL UNIT Key off timer circuit A18 A19...

Page 1879: ...he pulser the control unit makes the power window motor stop and reverse Disconnecting the battery Removing the No 79 20A fuse in the under hood subfuse box Disconnecting the 18P connector from the po...

Page 1880: ...Remove the driver s door panel see page 20 7 2 Disconnect the 18P connector A from the power window control unit B 3 Inspect the connector and socket terminals to be sure they are all making good con...

Page 1881: ...e relay box socket 13 BLK WHT Ignition switch ON II and driver s window switch UP Check for voltage to ground There should be battery voltage Faulty power window master switch Faulty power window rela...

Page 1882: ...ulty pulser An open in the wire 9 YEL BLU 5 GRN RED While operating the driver s window switch Check for voltage between the No 5 and No 9 terminals There should be pulse voltage An analog voltmeter n...

Page 1883: ...ore testing the power window control functions troubleshoot the multiplex control system see page 22 244 2 Remove the driver s multiplex control unit from the driver s under dash fuse relay box 3 Insp...

Page 1884: ...switch A19 Power window main switch ON and ignition switch ON II jump 12 V to A19 Check the left rear window motor operation The window should open Blown No 7 7 5A fuse in the passenger s under dash...

Page 1885: ...ultiplex control unit connector A 6 Remove the passenger s multiplex control unit from the passenger s under dash fuse relay box and disconnect its connectors 7 Inspect the connector and socket termin...

Page 1886: ...right rear power window operation The window should close Blown No 16 7 5A fuse in the passenger s under dash fuse relay box Faulty right rear window open relay Faulty right rear window close relay A...

Page 1887: ...10 Remove the door multiplex control unit from the driver s door and disconnect its connectors 11 Inspect the connector and socket terminals to be sure they are all making good contact If the terminal...

Page 1888: ...The window should go up reverse the wires for down Faulty driver s window motor An open in the wire A10 13 Reconnect the door multiplex control unit and perform the following input test If any test in...

Page 1889: ...YEL GRN RED GRN BLK BLK WHT BLU GRN BLU ORN BLK BLK 15 Remove the door multiplex control unit from the driver s door and disconnect its connectors 16 Inspect the connector and socket terminals to be...

Page 1890: ...tiplex control unit Faulty power window relay Poor ground G581 An open in the wire A12 BLK Under all conditions Check for continuity to ground There should be continuity Poor ground G401 G551 An open...

Page 1891: ...s to run smoothly replace it 5 Connect the test leads of an analog ohmmeter to the No 3 and No 4 terminals 6 Run the motor by connecting power and ground to the No 1 and No 2 terminals The ohmmeter ne...

Page 1892: ...average voltage between 0 5 V Connect an analog voltmeter between the B1 and B2 terminals and run the window motor at down or up The voltmeter needle should move back and forth alternately a digital...

Page 1893: ...rear window motor 3 Check window motor operation by connecting power and ground according to the table When the motor stops running disconnect one lead immediately 4 If the motor does not run or fail...

Page 1894: ...and master switch assembly from the door panel 2 Remove the four mounting screws then remove the master switch A from the panel B 1 Remove the screw and passenger s window switch assembly from the do...

Page 1895: ...FUSE RELAY BOX A 99 02 models MULTI RELAY BOX 03 04 models INTERMITTENT WIPER RELAY Test page 22 229 Replacement page 22 231 Replacement page 22 231 Test page 22 222 Replacement page 22 222 Wire colo...

Page 1896: ...SHER RESERVOIR WINDSHIELD WASHER MOTOR REAR WINDOW WIPER INTERMITTENT CONTROL UNIT 01 04 models Test page 22 229 Replacement page 22 232 Replacement page 22 232 Test page 22 230 Test page 22 230 Repla...

Page 1897: ...SHER SWITCH LO HI A7 G301 G301 G201 BLK BLK BLK YEL GRN RED GRN BLK GRN BLK BLK BLU WHT BLU WHT BLK BLU BLU YEL A3 A4 A8 A5 A2 A1 OFF INT LO HI GRN BLK YEL OFF INT MIST MIST YEL GRN No 9 10A BLK YEL I...

Page 1898: ...B15 A3 A8 B1 A24 PCM BLK YEL A11 A23 BLU WHT GRN RED BLU WHT A9 GRN PASSENGER S MULTIPLEX CONTROL UNIT INTERMITTENT DWELL TIME CONTROLLER No 47 20A FUSE BRAKE PEDAL POSITION SWITCH INTERMITTENT WIPER...

Page 1899: ...552 BLK G201 BLK GRN YEL B5 B1 B2 B7 B3 LT GRN BLK OFF ON BLK GRN YEL GRN BAT IG1 UNDER HOOD FUSE RELAY BOX BATTERY No 42 50A No 41 120A G401 YEL GRN BLK YEL WHT IGNITION SWITCH DRIVER S UNDER DASH FU...

Page 1900: ...UNIT No 11 10A 3 2 4 1 BLK YEL GRN G552 G201 BLK B5 B1 B7 B3 LT GRN BLK OFF ON BLK GRN YEL GRN BAT IG1 UNDER HOOD FUSE RELAY BOX BATTERY No 42 50A No 41 120A YEL GRN BLK YEL WHT IGNITION SWITCH DRIVE...

Page 1901: ...dels A B 1 Remove the driver s dashboard lower cover see page 20 69 2 Remove the steering column covers see page 17 25 3 Disconnect the connectors A from the wipers washers switch B then remove the tw...

Page 1902: ...A4 A5 A7 A8 B4 B8 0 30 k Terminal Position OFF Wiper and Washer switch ON B1 B2 B3 B5 B7 ON Washer switch ON and wiper switch OFF Terminal Position OFF Wiper and Washer switch ON B1 B3 B5 B7 ON Washer...

Page 1903: ...trim panel see page 20 60 2 Disconnect the 8P connector A from the rear window intermittent wiper control unit B 3 Inspect the connector and socket terminals to be sure they are all making good contac...

Page 1904: ...An open in the wire 5 Reconnect the rear window wiper intermittent control unit and make these input tests If any test indicates a problem find and correct the cause then recheck the system If all th...

Page 1905: ...ing the wiper washer control functions troubleshoot the multiplex control system see page 22 244 2 Remove the driver s multiplex control unit from the driver s under dash fuse relay box and disconnect...

Page 1906: ...Ignition switch ON II wiper switch in the PARK position Check for voltage to ground There should be battery voltage Faulty intermittent wiper relay An open in the wire A24 Ignition switch ON II Check...

Page 1907: ...the terminals look OK go to step 8 8 With the passenger s multiplex control unit still disconnected make these input tests at the connector and the fuse relay box socket If any test indicates a probl...

Page 1908: ...e motor at low or high speed The voltmater should indicate 12 V and 4 V or less alternately 6 If the motor test is not as specified replace the windshield wiper motor 1 Open the tailgate and remove th...

Page 1909: ...motor runs smoothly but little or no washer fluid is pumped check for a disconnected or blocked washer hose or a clogged pump outlet in the motor 1 Remove the right inner fender see page 20 149 2 Dis...

Page 1910: ...kage assembly D toward the passenger s side of the vehicle until it slides off of the pin E then remove the assembly 5 Scribe a line A across the link and windshield wiper linkage to show the original...

Page 1911: ...e lower trim panel see page 20 61 2 Remove the mounting nut A the wiper arm B and the special nut C 3 Disconnect the 4P connector A and remove the three mounting bolts B then remove the rear window wi...

Page 1912: ...22 233 Washer Tube Replacement 1 Remove the right inner fender see page 20 149 2 Remove the washer nozzles and clips then remove the tubes cont d...

Page 1913: ...22 234 Wipers Washers Washer Tube Replacement cont d 3 Install in the reverse order of removal Take care not to pinch the washer tubes Check the washer operation...

Page 1914: ...R RECEIVER UNIT TRANSPONDER PCM IGNITION KEY 99 02 models TRANSPONDER IGNITION KEY 03 04 models F type keys only Bulb Location page 22 95 Troubleshooting page 22 239 Replacement page 22 240 Built into...

Page 1915: ...h Door locks When the key is inserted in the ignition switch and turned to the II position the immobilizer receiver unit sends power to the transponder in the ignition key The transponder then sends a...

Page 1916: ...ds to signal that the immobilizer system has been set correctly then the indicator will go off NOTE Large metal objects key fobs other immobilizer keys and other transpondars can interfere with the im...

Page 1917: ...P IMOEN IMOCD IGP2 IGP1 IMOFLR G101 G551 BLK G101 BRN BLK PCM YEL BLK YEL BLK YEL BLK BRN BLK BLU 1 4 3 2 RED IMMOBILIZER RECEIVER UNIT KEY PNK WHT YEL BLK BLK YEL GRN YEL YEL BLK WHT GRN BLU ORN RED...

Page 1918: ...TC see page 11 3 Replace the PCM Go to step 2 2 Turn the ignition switch ON II with the proper key 3 Check to see if the immobilizer indicator light comes on Go to step 4 Check for these problems an o...

Page 1919: ...ntinuity between the No 3 terminal and PCM 99 00 models connector A No 13 terminal 01 model connector E No 30 terminal 02 04 models connector E No 12 terminal Replace the immobilizer receiver unit Rep...

Page 1920: ...x PASSENGER S MULTIPLEX CONTROL UNIT IGNITION KEY LIGHT DOOR MULTIPLEX CONTROL UNIT DRIVER S MULTIPLEX CONTROL UNIT MULTIPLEX CONTROL INSPECTION CONNECTOR Has built in beeper Test page 22 145 Built in...

Page 1921: ...0A No 54 40A YEL A1 WHT YEL G551 BLK BRN A12 WHT YEL 10A A8 BLK G581 3 1 A15 BLU WHT PNK A24 WHT YEL BLK A24 G401 WHT YEL BLK BLK BLK 3 1 A13 A14 A1 WHT BLK No 9 BATTERY No 42 50A UNDER HOOD FUSE RELA...

Page 1922: ...BRN Driver s Passenger s between the driver s and the passenger s multiplex control units Wire color PNK The control units always communicate via these lines when the system is operating and they sto...

Page 1923: ...se in the driver s under dash fuse relay box and the No 13 7 5A fuse in the Passenger s under dash fuse relay box Go to step 2 Find and repair the cause of the blown fuse 2 Connect the special tool to...

Page 1924: ...inal of the driver s fuse relay box socket and body ground Go to step 11 Repair an open in the wire between No 13 fuse in the passenger s under dash fuse relay box and the driver s under dash fuse rel...

Page 1925: ...between driver s multiplex control unit connector B and ground If the wire is OK check for door ground at G501 13 Check for continuity between No 1 terminal of the MPCS inspection connector and the N...

Page 1926: ...ion key light should come on and the beeper should beep for 2 seconds then blink beep twice more at 0 2 second intervals This indicates the system has entered mode 2 2 Operate the switch as described...

Page 1927: ...oil pressure indicator see page 22 110 Find the open or short in the circuit that was not confirmed by the multiplex control system If the circuit is OK replace the multiplex control unit that monito...

Page 1928: ...and the passenger s multiplex B 22P connector 1 Remove the driver s multiplex control unit from the driver s under dash fuse relay box 2 Carefully pry off the driver s door switch trim see page 20 7...

Page 1929: ...Check for voltage to ground There should be battery voltage Blown No 13 7 5A fuse in the passenger s under dash fuse relay box Blown No 54 40A fuse in the under hood fuse relay box An open in the wire...

Page 1930: ...e relay box and disconnect its connectors 5 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary...

Page 1931: ...01 An open in the wire A24 Ignition switch ON II Check for voltage to ground There should be battery voltage Blown No 9 10A fuse in the driver s under dash fuse relay box An open in the wire A13 Ignit...

Page 1932: ...d There should be continuity Poor ground G503 An open in the wire A24 Fuse relay box socket Under all conditions Check for voltage to ground There should be battery voltage Blown No 13 7 5A fuse in th...

Page 1933: ...EX models Factory Security Alarm System 01 04 EX and 02 04 EXL models TAILGATE LOCK ACTUATOR KNOB SWITCH LATCH SWITCH KNOB SWITCH LEFT SLIDING DOOR LOCK ACTUATOR KNOB SWITCH DRIVER S DOOR LOCK ACTUAT...

Page 1934: ...SSENGER S MULTIPLEX CONTROL UNIT SECURITY INDICATOR HOOD SWITCH 01 04 EX and 02 04 EXL models KNOB SWITCH FRONT PASSENGER S DOOR LOCK ACTUATOR Test page 22 283 Replacement page 20 8 Test page 22 284 A...

Page 1935: ...to confirm the security alarm system is armed will sound if the LOCK button is pressed a second time within 5 seconds If one of the switches is misadjusted or there is a short in the system the syste...

Page 1936: ...d time When the switch for the ceiling light is in the center position it will come on when you press the UNLOCK button If you do not open a door the light will go off in about 30 seconds the doors wi...

Page 1937: ...B11 DRIVER S MULTIPLEX CONTROL UNIT B16 BATTERY No 41 120A No 42 50A UNDER HOOD FUSE RELAY BOX 15A No 10 WHT IGNITION SWITCH BAT IG1 No 9 10A PASSENGER S UNDER DASH FUSE RELAY BOX DRIVER S UNDER DASH...

Page 1938: ...RECEIVER UNIT Fuse relay box socket WHT YEL A24 PASSENGER S MULTIPLEX CONTROL UNIT A9 BLK WHT A21 A23 YEL A22 No 47 20A FUSE DRIVER S MULTIPLEX CONTROL UNIT INTERIOR LIGHTS SWITCH HORN SWITCH LOW HOR...

Page 1939: ...WHT RED BLK BLK G552 BLK 1 2 2 1 GRN BLK 1 1 2 1 2 BLK ORN BLK BLU LOCK LT GRN RED WHT RED 2 1 1 2 WHT RED LT GRN RED LT GRN RED WHT RED YEL B11 A10 LT GRN RED 2 1 A11 UNLOCK LOCK PASSENGER S MULTIPLE...

Page 1940: ...10 A4 BLU RED A8 WHT RED WHT RED WHT RED A5 D3 D2 BLK A3 YEL RED UNLOCK LOCK LT GRN RED WHT RED LEFT POWER SLIDING DOOR CONTROL UNIT FUEL FILL DOOR RELAY FUEL FILL DOOR SWITCH Closed Fill door open No...

Page 1941: ...6 GRN RED BLK WHT DOOR MULTIPLEX CONTROL UNIT WHT YEL BRN LOCK UNLOCK UNLOCK A15 A17 BLK RED 3 1 2 A7 PNK UNLOCK LOCK 3 1 2 2 1 BLK A16 BLU BLK A12 A8 A18 A1 G401 BLK BLK BLK DRIVER S MULTIPLEX CONTRO...

Page 1942: ...K B11 DRIVER S MULTIPLEX CONTROL UNIT B16 BATTERY No 41 120A No 42 50A UNDER HOOD FUSE RELAY BOX 15A No 10 WHT IGNITION SWITCH BAT IG1 No 9 10A PASSENGER S UNDER DASH FUSE RELAY BOX DRIVER S UNDER DAS...

Page 1943: ...K UNLOCK B9 PNK PANIC UNLOCK LOCK RED YEL GRN BLU YEL WHT YEL PNK BLK RED WHT 3 14 GRN BLK GRN BLU 13 2 GRN ORN 10 BLK G503 BLU WHT KEYLESS RECEIVER UNIT Fuse relay box socket WHT YEL A24 PASSENGER S...

Page 1944: ...WHT RED A8 BLU RED A4 SLIDING DOOR LOCK CONTROL UNIT 2 2 1 9 H 2 3 1 10 8 1 1 2 BLU BLK G552 WHT GRN WHT WHT J I BLK D3 D4 BLU WHT G551 BLK LEFT POWER SLIDING DOOR CONTROL UNIT FUEL FILL DOOR RELAY FU...

Page 1945: ...K WHT GRN RED G552 BLK 1 2 2 1 1 DOOR MULTIPLEX CONTROL UNIT WHT YEL BRN LOCK UNLOCK UNLOCK A15 A17 BLK RED 3 1 2 A7 PNK UNLOCK LOCK 3 1 2 2 1 BLK A16 BLU BLK A12 A8 BLK WHT GRN RED A18 A1 G401 BLK BL...

Page 1946: ...EXL 2 EX 02 04 EXL RED BLU 2 2 1 1 1 Before testing the keyless entry power door lock control functions troubleshoot the multiplex control system see page 22 244 2 Remove the driver s multiplex contr...

Page 1947: ...passenger s under dash fuse relay box An open in the wire A24 Ignition switch ON II Check for voltage to ground There should be battery voltage Blown No 9 7 5A fuse in the driver s under dash fuse rel...

Page 1948: ...ould be 5 V or more A10 GRN YEL Left sliding door open Check for voltage to ground There should be less than 1 V Faulty left sliding door switch An open in the wire Short to ground Left sliding door c...

Page 1949: ...BOX CONNECTOR F PNK BLK RED YEL LT GRN RED BLK GRN BLK RED BLU Passenger s multiplex control unit connector A 01 04 EX 02 04 EXL 6 Remove the passenger s multiplex control unit from the passenger s u...

Page 1950: ...22 271 PASSENGER S UNDER DASH FUSE RELAY BOX CONNECTOR I GRN WHT PASSENGER S UNDER DASH FUSE RELAY BOX CONNECTOR J ORN BLK BLU 01 04 EX 02 04 EXL cont d Wire side of female terminals...

Page 1951: ...e passenger s under dash fuse relay box Faulty passenger s under dash fuse relay box A24 Under all conditions Check for voltage to ground There should be battery voltage Blown No 13 7 5A fuse in the p...

Page 1952: ...ck for voltage to ground There should be 5 V or more F6 BLK ORN Front passenger s door lock switch in LOCK Check for voltage to ground There should be 1 V or less Front passenger s door lock switch in...

Page 1953: ...bent loose or corroded repair them as necessary and recheck the system If the terminals look OK go to step 12 12 With the door unit still disconnected make these input tests at the connector If any t...

Page 1954: ...r An open in the wire Driver s door lock knob locked Check for voltage to ground There should be 5 V or more A8 BLK WHT Driver s door lock switch in LOCK Check for voltage to ground There should be le...

Page 1955: ...GRN BLK 1 Remove the glove box see page 20 71 2 Disconnect the 14P connector A from the keyless receiver unit B 3 Inspect the all connector and socket terminals to be sure they are all making good co...

Page 1956: ...rily Check horn operation The horns should sound An open in the wire Short to ground Faulty passenger s multiplex control unit 5 Reconnect the connector to the control unit and perform the following i...

Page 1957: ...the keyless receiver unit memory If a fourth code is stored the code which was input first will be erased NOTE It is important to maintain the time limits between the steps Make sure the doors the hoo...

Page 1958: ...prevent damage to the actuator apply battery voltage only momentarily 4 If the actuator does not operate as specified replace it 1 Remove the front passenger s door panel see page 20 7 2 Disconnect th...

Page 1959: ...rding to the table To prevent damage to the actuator apply battery voltage only momentarily 4 If the actuator does not work as specified replace it 1 Remove the right sliding door panel see page 20 13...

Page 1960: ...ty between the No 2 and No 3 terminals in each switch position There should be continuity with the knob switch in UNLOCK There should be no continuity with the knob switch in LOCK 5 If the continuity...

Page 1961: ...in each switch position according to the table 4 If the continuity is not as specified replace the switch 1 Remove the right sliding door panel see page 20 13 2 Disconnect the connector A from the ac...

Page 1962: ...ck for continuity between the terminals in each switch position according to the table 4 If the continuity is not as specified replace the switch 1 Remove the front passenger s door panel see page 20...

Page 1963: ...cified replace the switch 1 Remove the inner door handle see page 20 7 2 Remove the two screws A then remove the door lock switch B 3 Check for continuity between the No 1 and No 2 terminals in each s...

Page 1964: ...uator apply battery voltage only momentarily 4 If the actuator does not operate as specified replace it 1 Remove the tailgate trim panel see page 20 61 2 Disconnect the 3P connector A from the actuato...

Page 1965: ...e hood switch 3 Check for continuity between the terminals There should be continuity between the No 1 and No 2 terminals when the hood is opened lever released There should be no continuity between t...

Page 1966: ...FUSE RELAY BOX A 99 02 models REMOTE CONTROL SWITCH REMOTE CONTROL SWITCH No 81 30A FUSE UNDER HOOD SUB FUSE BOX 03 04 models LEFT POWER SLIDING DOOR CONTROL UNIT LATCH POSITION SWITCH RELEASE MOTOR...

Page 1967: ...on the power sliding door switch once Pull either of the inner or outer door handles once Child safety lock must be off for inner handle to open the door Press the sliding door button on the keyless...

Page 1968: ...ch on the keyless transmitter is pressed At this time the warning buzzer sounds in the following interval and the doors cannot be operated until the warning buzzer stops When the shift lever is in any...

Page 1969: ...ator light If the light comes on for 2 seconds and then goes off there is an intermittent problem Erase the DTC s do the re homing procedure and recheck the system If the light stays on go to step 4 4...

Page 1970: ...he passenger s under dash fuse relay box for 10 seconds and reinstall the fuse 4 Turn the main switch ON 5 Confirm proper operation of the power sliding doors using the door switches door handles and...

Page 1971: ...es not move The beeper sounds three times The door lock knob will not stay in the unlocked position unless it is held there for several seconds The fuel fill door switch or circuit Perform the followi...

Page 1972: ...switch is pushed the release motor operates and the door opens about 9 inches The half latch switch junction switch control unit or circuit Perform the following tests Closer Motor Latch Switch Posit...

Page 1973: ...2 3 4 Faulty CLOSE switch in the power sliding door switch A short to body ground in the wire of the DRCL circuit A short to body ground in the wire of the SCOM circuit Faulty power sliding door contr...

Page 1974: ...hood sub fuse box 03 model Blown No 52 30A fuse in the under hood fuse relay box An open in the BLK wire of the PGND1 circuit Poor ground G552 G582 An open in the wire of the SLMOP circuit An open in...

Page 1975: ...B2 A14 GRN WHT YEL WHT YEL IGNITION SWITCH IG1 BAT No 9 10A YEL RED YEL No 5 20A 20A No 1 WHT No 81 30A YEL WHT BLU YEL GRN WHT RED No 54 40A No 51 40A No 55 40A No 52 30A UNDER HOOD FUSE RELAY BOX WH...

Page 1976: ...GRN GRN RED GRN BLK 4 F L A9 A1 CLM GRN BLK 2 BLU YEL BLU WHT 1 BLU YEL B1 B3 C1 C2 2 1 BLK G552 RED WHT RED WHT RED WHT B4 BUZZER REM A3 CLM A2 LEFT POWER SLIDING DOOR CONTROL UNIT GRN ORN A22 A10 GR...

Page 1977: ...TION SENSOR LT GRN BLK A15 SLSE2 3 1 SEGND A5 PNK BLK RED BLK A17 SLSE1 2 4 VREF SLMCL SLMOP B3 GRN RED 2 1 A16 YEL IG1 VMP1 VMP2 VBU VSP IND PCM YEL BLK A11 A22 BLU WHT WHT YEL A14 A25 RED YEL WHT RE...

Page 1978: ...GRN BLK 2 BLU YEL BLU WHT 1 BLU YEL B1 B3 C1 C2 RED WHT B4 BUZZER REM A13 CLM A12 RIGHT POWER SLIDING DOOR CONTROL UNIT RED WHT A20 A18 GRN BLK KESG KERQ BLU BLK RED WHT Body side 6 7 7 8 BLU BLK LT G...

Page 1979: ...RN YEL GRN 1 99 01 models 2 02 04 models 1 2 1 2 1 Remove the left rear side trim panel see page 20 60 2 Remove the left power sliding door control unit see page 22 320 3 Disconnect the 26P connector...

Page 1980: ...e A14 terminal to the A1 terminal and the A2 terminal to the A15 terminal to return the closer motor Check the closer motor operation The closer motor should move the latch to the starting position Th...

Page 1981: ...eck for continuity between the A23 terminal and the sliding motor revolution sensor No 4 terminal There should be continuity An open in the wire A25 PNK BLK Under all conditions Check for continuity b...

Page 1982: ...or switch Faulty fuel fill door relay An open in the wire Short to ground Fuel fill door close Check for voltage to ground There should be battery voltage A6 RED WHT Without sliding the door open move...

Page 1983: ...99 01 models 2 02 04 models BLK BLU BLU BLK 1 1 2 1 Remove the right rear side trim panel see page 20 60 2 Remove the right power sliding door control unit see page 22 320 3 Disconnect the 26P connect...

Page 1984: ...nal and the A1 terminal to the A12 terminal to return the closer motor Check the closer motor operation The closer motor should move the latch to the starting position The motor should operate only on...

Page 1985: ...onditions Check for continuity between the A18 terminal and the keyless receiver unit No 14 terminal There should be continuity An open in the wire A20 RED WHT Under all conditions Check for continuit...

Page 1986: ...Check for voltage to ground There should be battery voltage A9 RED WHT Without sliding the door open move the inside door handle to the rear of the vehicle Check for voltage between the A9 terminal a...

Page 1987: ...s again using all three methods and listen for the warning beeper Go to step 4 Go to step 5 4 With the MAIN switch turned OFF compare the manual door opening closing force between the left and right d...

Page 1988: ...able The doors move very quickly Do not allow the motor to slam the door open or closed 4 If the motor does not run or fails to run smoothly replace it 1 Remove the left rear side trim panel see page...

Page 1989: ...ion FORWARD REVERSE B1 B3 1 Remove the sliding door panel see page 20 13 2 Disconnect the 6P connector from the motor and switch 3 Test the closer motor by connecting power and ground according to the...

Page 1990: ...panel see page 20 13 2 Disconnect the 4P connector from the release motor and switch 3 Test the release motor by connecting power and ground according to the table 4 Check for continuity between the...

Page 1991: ...LOSE OPEN CLOSE 7 Terminal Position ON OFF 1 10 1 2 Disconnect the 10P connector A from the power sliding door switch B 3 Check for continuity between the terminals in each switch position according t...

Page 1992: ...eft A B 1 2 3 4 5 A B C D G 6 7 8 9 10 E F H I J 1 Remove the center pillar trim see page 20 58 2 Disconnect the 10P connector A from the switch B 3 Check for continuity between the terminals accordin...

Page 1993: ...H I J K K J I H F E D C B A G 7 8 9 10 11 12 E F H I J K 1 2 3 4 6 A B C D G 1 Remove the sliding door panel see page 20 13 2 Disconnect the 12P connector A from the switch B 3 Check for continuity b...

Page 1994: ...RED WHT BLU WHT A A B C D E F G B1 B3 B4 H I J K A3 A5 A6 D1 A4 A8 B6 D2 C2 D4 C3 C4 E2 D1 B5 E3 E1 C1 D3 1 Remove the sliding door panel see page 20 13 2 Disconnect the connectors from the switch A 3...

Page 1995: ...B C D E F G H I J F D C B A K J I H G BLU RED BLU WHT E K RED WHT A A B C D E F G B1 B3 B4 H I J K A3 A5 A6 D1 A4 A8 B6 D3 C2 D5 C3 C4 E2 D2 B5 E3 E1 C1 D6 E4 1 Remove the sliding door panel see page...

Page 1996: ...ct the 2P connector from the sliding door handle switch A 2 Remove the two mounting screws from the switch 3 Check for continuity between the terminals in each switch position according to the table 4...

Page 1997: ...hile slowly sliding the door manually check for voltage between the power sliding door control unit terminals A26 and A24 There should be 0 to about 5 V repeatedly If there is no voltage check the fol...

Page 1998: ...y sliding the door manually check for voltage between the power sliding door control unit terminals A17 and A2 There should be 0 to about 5 V repeatedly If there is no voltage check the following a fa...

Page 1999: ...ove the seat belt tensioner for the second row seat see page 23 8 3 Remove the three mounting screws A from the power sliding door control unit B 4 Disconnect the 26P and 5P connectors C from the cont...

Page 2000: ...FILL DOOR SWITCH LEFT SLIDING DOOR LOCK ACTUATOR KNOB SWITCH FUEL FILL DOOR RELAY SLIDING DOOR JUNCTION SWITCH SLIDING DOOR LOCK CONTROL UNIT Actuator Test page 22 280 Knob Switch Test page 22 282 Te...

Page 2001: ...2 2 1 9 H 2 3 1 10 8 1 1 2 LT GRN RED WHT RED BLU BLK G552 WHT GRN WHT WHT 20A No 12 UNDER HOOD FUSE RELAY BOX BATTERY No 41 120A No 54 40A YEL J I BLK D3 D4 BLU WHT G551 BLK PASSENGER S UNDER DASH F...

Page 2002: ...G552 WHT GRN WHT WHT 20A No 12 UNDER HOOD FUSE RELAY BOX BATTERY No 41 120A No 54 40A YEL K J BLK D6 D5 BLU WHT G551 BLK PASSENGER S UNDER DASH FUSE RELAY BOX DRIVER S MULTIPLEX CONTROL UNIT PASSENGER...

Page 2003: ...ng door panel see page 20 13 2 Disconnect the 8P connector A from the sliding door control unit B 3 Inspect the connector and socket terminals to be sure they are all making good contact If the termin...

Page 2004: ...tor to the control unit and make this input test If a test indicates a problem find and correct the cause then recheck the system If the input test proves OK the control unit must be faulty replace it...

Page 2005: ...A3 A4 A5 A6 A8 H I J D2 D4 1 Remove the center pillar trim see page 20 58 2 Disconnect the connector A from the junction switch B 3 Check for continuity between the terminals according to the table 4...

Page 2006: ...he 12P connector A from the junction switch B 3 Check for continuity between the terminals according to the table 4 If the continuity is not as specified replace the switch 1 Remove the left sliding d...

Page 2007: ...VER S SEAT CUSHION HEATER FRONT PASSENGER S SEAT HEATER SWITCH DRIVER S SEAT HEATER SWITCH SEAT HEATER RELAY EXL MULTI FUSE RELAY BOX B 02 model Test page 22 330 Wire colors WHT GRN WHT BLK BLK and YE...

Page 2008: ...BLK WHT BLK 6 2 1 5 3 4 5 6 2 4 RED 2 G401 WHT BLK SEAT HEATER RELAY WHT GRN No 42 50A No 41 120A UNDER HOOD FUSE RELAY BOX BAT IG2 IGNITION SWITCH WHT YEL 7 5A No 4 YEL BLK BLK G301 BATTERY HI High L...

Page 2009: ...nt seat see page 20 81 2 Driver s seat Check for continuity between the No 2 and No 3 terminals and No 3 and No 4 terminals of the driver s seat heater heater connector 4P There should be continuity I...

Page 2010: ...AR CONTROLLER and SCREEN AUXILIALY JACK ASSEMBLY WIRELESS HEADPHONE WIRELESS REMOTE CONTROL Replacement page 22 161 Removal Installation page 22 342 Replacement page 22 161 Test page 22 160 Replacemen...

Page 2011: ...control of the rear system Offers simple operation control in the audio unit Has the ability to play DVDs or CDs Automatically turns off when battery voltage drops below 12 volts Has flip down 7 displ...

Page 2012: ...rn left to select the front controls Audio Turn right to select the rear controls After rear operation is finished selector will automatically return to the front control in 10 seconds 3 Rear control...

Page 2013: ...automatic OFF function By turning the rear speaker OFF you can reduce the interference between the front source and the rear source Headphone The speaker will be turned ON OFF automatically when the f...

Page 2014: ...A13 Not used A4 BLU DVD player unit Security input A14 Not used A5 RED YEL Right rear speaker A15 BRN WHT Right rear speaker A6 BLU YEL Left rear speaker A16 GRY WHT Left rear speaker A7 RED GRN Pass...

Page 2015: ...en BUS data output B8 BLU GRN Rear controller and screen BUS ground B16 BRN Rear controller and screen BUS shielding C1 ORN DVD player unit L ch1 C12 ORN BLU DVD player unit R ch1 C2 BLU GRN DVD playe...

Page 2016: ...N WHT Audio unit serial shielding A8 Not used A21 Not used A9 BLU Audio unit video 1 A22 RED Audio unit video 1 ground A10 Not used A23 BRN BLK Audio unit video 1 shielding A11 BLU Audio unit security...

Page 2017: ...t audio 3 ground 12 GRN DVD player unit R ch3 13 ORN Audio unit headphone L ch output 14 ORN BLU Audio unit headphone R ch output When replacing a rear controller and screen connector match the wires...

Page 2018: ...s every 3 seconds for the DVD player unit DVD the rear controller and screen DISP and auxiliary AUX 5 When there is no problem found the system returns to normal operation automatically followed by a...

Page 2019: ...IGHT TWEETER G581 WHT RED BLK WHT RED YEL BLK GRY BLK BLU GRN RED GRN BRN BLK BATTERY No 54 40A UNDER HOOD FUSE RELAY BOX No 42 50A YEL WHT BLK BAT ACC RED BLK No 8 7 5A WHT RED GRY WHT BLU YEL RED YE...

Page 2020: ...2 ACC B 1 WHT BLU ILL 13 RED BLK BLU GRN 7 VIDEO2 GRN 9 AUDIO UNIT ILL SCTY IN GND BLK 14 WHT BLU R CH L CH GND 26 RED 5 GRN YEL 4 17 BLU BRN WHT 18 BLU 22 BLK 15 G552 REAR CONTROLLER and SCREEN COMB...

Page 2021: ...lead B from the audio unit 4 Remove the bolts C 5 Remove the screws A and the audio unit 6 Install in the reverse order of removal and note these items Make sure the audio unit connectors and the ant...

Page 2022: ...tect your hands Take care not to scratch the headliner and display cover 1 Remove the display cover A 2 Remove the mounting bolts A 3 Disconnect the connector B from the rear controller and screen C 4...

Page 2023: ...nting screws from the lock switch A and base B 8 Install in the reverse order of removal and make sure the rear controller and screen connector is plugged in properly 1 Remove the battery covers A fro...

Page 2024: ...panel see page 20 60 2 Disconnect the 14P connector A from the auxiliary jack assembly B 3 Carefully pry the auxiliary jack assembly out of the left rear side trim panel 4 Install in the reverse orde...

Page 2025: ......

Page 2026: ...am 22 364 Symptom Troubleshooting 22 366 System Diagnosis Test 22 376 Forced Starting of Display 22 383 DVD ROM Replacement 22 383 Vehicle Speed Pulse VSP Sensor Replacement 22 384 Navigation Unit Rem...

Page 2027: ...Ref No Tool Number Description Qty 22 348 Navigation System Special Tools 07PAZ 0010100 SCS Service Connector 1 07LAJ PT3020A Test Harness 00 01 models 1 03 07 29 10 27 47 61S0X050_220_0350...

Page 2028: ...GATION UNIT VEHICLE SPEED PULSE VSP SENSOR NAVIGATION SERVICE CHECK CONNECTOR Removal Installation page 22 385 Removal Installation page 22 342 Removal Installation page 22 385 Removal Installation pa...

Page 2029: ...such as by ferry or tow truck or if the vehicle is spun on a turn table Tire slippage changes in tire rolling diameters and some driving situations may cause discrepancies in travel distances Example...

Page 2030: ...was experiencing Vibration temperature extremes and moisture dew humidity are factors that are difficult to duplicate Inspect the vehicle for after market electronic devices vehicle locators amp radar...

Page 2031: ...ies Audio driving instructions cannot be heard Troubleshooting see page 22 370 Vehicle position wanders on the map see page 22 373 Vehicle position wanders on the map Troubleshooting see page 22 373 S...

Page 2032: ...P 4 WHT R SIG Red signal Red color signal 5 RED G SIG Green signal Green color signal 6 BRN BLK SH SIG Shield signal Shield for terminal No 4 5 10 11 12 10 YEL B SIG Blue signal Blue color signal 11 G...

Page 2033: ...Shield route guidance Shield for terminal No 1 9 10 3 WHT BLK MUTE Mute Audio mute signal 7 BLU GRN DISP BUS Display bus positive Data bus 8 RED BLK ILL Illumination positive Parking light ON signal...

Page 2034: ...HT BLU CHG Charge Engine ON signal 4 BLK GND Ground Ground for navigation unit 5 GRN BLK BACK LT Back light Reverse signal of select lever 6 BLU WHT VSP Vehicle speed pulse Vehicle speed pulse signal...

Page 2035: ...G SIG Green signal Green color signal 10 BLK GND Ground Ground for display unit 11 RED BLK ILL Illumination positive Parking light ON signal 12 RED ILL Illumination negative Parking light ON signal 14...

Page 2036: ...eral of these satellites the navigation system can determine the latitude and longitude of the vehicle In addition signals from the system s yaw rate sensor and the vehicle speed pulse VSP sensor enab...

Page 2037: ...stance GPS tuning Detection of direction change DVD ROM Map scroll Change of reduced scale of map Guide processing Destination VEHICLE SPEED PULSE VSP SENSOR 00 01 PCM 02 04 NAVIGATION UNIT Sensor pow...

Page 2038: ...parts and voltage is generated between both sides of the piezoelectoric parts when they are bent by an external force The oscillation gyro fuctions by utilizing this characteristic of the piezoelectri...

Page 2039: ...e display No satellite mark Two or less Impossible to detect vehicle position The GPS function is normal The satellite electronic waves received by the GPS receiver are too few to determine the vehicl...

Page 2040: ...on data with the GPS vehicle position data If there is a large difference between the two the indicated vehicle position is adjusted to the GPS vehicle position The distance tuning reduces the differe...

Page 2041: ...he DCA Hawaii and Alaska are outside of the DCA Detailed Coverage Areas Major city and metropolitan areas have detailed coverage of streets and addresses Outlying Areas Outlying areas have coverage of...

Page 2042: ...t uses liquid crystal display LCD The LCD is a 6 inch wide thin film transistor TFT stripe type with 280 800 picture elements The color film and fluorescent light are laid out on the back of the liqui...

Page 2043: ...SENGER S UNDER DASH FUSE RELAY BOX MULTIPLEX CONTROL UNIT DRIVER S LF SPEAKER RF SPEAKER RG L CLIMATE CONTROL UNIT CLK2 ACI ACO G501 GRN BLK WHT RED WHT BLU RED BLK RED BLK WHT RED WHT BLU RED BLK WHT...

Page 2044: ...RVICE CHECK CONNECTOR GPS VSP GPS ANTENNA GPS ANTENNA CONNECTOR GND GND GPS VEHICLE SPEED PULSE VSP SENSOR 00 01 PCM 02 04 GPS GND GPS NAVIGATION UNIT CONNECTORS NAVIGATION SERVICE CHECK CONNECTOR GPS...

Page 2045: ...Diagnosis Test menu see page 22 376 Go to step 6 6 Measure the voltage between body ground and navigation unit connector C 8P terminals No 1 and No 2 individually Go to step 7 Repair open in the wire...

Page 2046: ...r B 20P based on the missing color s Missing color Navigation unit connector A 12P Display unit connector B 20P Wire color Blue A10 B18 YEL Green A5 B9 RED Red A4 B8 WHT Go to step 5 There is an open...

Page 2047: ...relay box and the display unit 3 Check for continuity between display unit connector B 20P terminal No 10 and body ground Go to step 4 Repair the open in the wire between the display unit and body gr...

Page 2048: ...ck for poor connections or loose terminals at the display and navigation units If a poor connection or loose terminal is found replace the affected shielded harness NOTE Make sure the vehicle is parke...

Page 2049: ...the System Diagnosis Menu see page 22 376 Replace the navigation unit Go to step 5 3 Push the display unit MENU key and select set up 4 Check the audio driving instructions volume setting Set the volu...

Page 2050: ...to step 9 There is an open in the circuit between the navigation unit and the audio unit Replace the affected shielded harness 9 Check for continuity between navigation unit connector B 16P terminal N...

Page 2051: ...to step 11 Repair open in the wire between the navigation unit and the audio unit 11 Check for continuity between navigation unit connector B 16P terminal No 10 and the audio unit 20P connector termi...

Page 2052: ...e it is securely supported 5 Put the vehicle in neutral with the ignition switch ON II 6 Measure the voltage between body ground and navigation unit connector C 8P terminal No 6 7 Slowly rotate one wh...

Page 2053: ...e ignition switch OFF 17 Disconnect the navigation unit connector C 8P from the navigation unit 18 Disconnect the WHT and RED test harness clips 19 Connect the GRN test harness clip A to the positive...

Page 2054: ...n unit NOTE The next check will need to be done as the vehicle is driven You may want to save this test until last Have a helper monitor the screen as the vehicle is driven 5 Select tuning 6 Test driv...

Page 2055: ...Yaw Rate Unit Check Cyclic Diag Rear camera 03 04 Models Only In line Diag During diagnosis all of the communication lines connecting the components are shown in yellow If the system is OK all of the...

Page 2056: ...ould be within 0 01 V of each other If not replace the navigation unit Example NOTE The vehicle is stopped sitting still with the engine idling NOTE Do not try to tune the yaw rate sensor unless instr...

Page 2057: ...st Pattern White Raster Switch Check Black Raster Color Change Red Green Blue Return Return Select the item you want to check and the check starts The three primary colors of red green and blue must b...

Page 2058: ...Color No Each switch must be shown on the display and each switch must reverse and sound when touched NOTE The test may be affected if done in direct sunlight All 32 colors including black must be ind...

Page 2059: ...check for loose terminals at the navigation unit and the display unit connectors Next check for an open or short in the communication line between the navigation unit and the display unit If the line...

Page 2060: ...atch the actual vehicle status check the applicable signal line VSP vehicle speed pulse indication OFF when vehicle is not moving ON when vehicle is moving BACK reverse indication OFF when shift lever...

Page 2061: ...will turn off until the temperature cools down Outside temperature is low system will take a while to start up The temperature is below 30 C and the navigation ECU has difficulties reading the DVD If...

Page 2062: ...switch to ACC I NOTE If the display fails to light or the system link screen is not displayed refer to no picture is shown on the display see page 22 366 NOTE When the DVD ROM is re inserted or repla...

Page 2063: ...C then remove the VSP 3 Install the VSP Lubricate the new O ring D and the vehicle speed pulse VSP sensor joint E with grease before installing 1 Remove the navigation unit guard A from the bracket 2...

Page 2064: ...rse order of removal 1 Remove the center panel see page 20 70 2 Remove the Instrument panel see page 20 69 3 Remove the center lower console see page 20 68 4 Disconnect the GPS antenna connector A 5 R...

Page 2065: ...select Display Off 5 Touch the numbers of the clock to change the clock size and location If the clock is small and in the lower right hand corner of the screen it will increase in size and move to t...

Page 2066: ...om Troubleshooting Index 23 54 System Description 23 56 Circuit Diagram 23 63 DTC Troubleshooting 23 68 Symptom Troubleshooting 23 337 Component Replacement Inspection After Deployment 23 367 Driver s...

Page 2067: ...1 07TAZ SZ5011A SRS Simulator Lead C 1 07TAZ 001020A Backprobe Adapter 17 mm 2 07XAZ S1A0200 SRS Simulator Lead E 1 07XAZ SZ30100 SRS Simulator Lead F 1 07YAZ S3AA100 SRS Simulator Lead H 1 070AZ SAA...

Page 2068: ...CHOR THIRD ROW SEAT BELT SECOND ROW SEAT BELT FRONT SEAT BELT SECOND ROW CHILD SEAT TETHER ANCHOR page 23 8 step 1 on page 23 13 Inspection page 23 15 step 1 on page 23 14 page 23 4 step 1 on page 23...

Page 2069: ...ke sure you have the anti theft code for the radio and the navigation system and then write down the frequencies for the preset buttons 2 Slide the front seat forward fully 3 Disconnect the negative c...

Page 2070: ...or adjuster A 13 Install the seat belt and retractor in the reverse order of removal and note these items Apply liquid thread lock to the anchor bolts before reinstallation Check that the retractor lo...

Page 2071: ...CHOR COLLARS TOOTHED LOCK WASHER LOWER ANCHOR BOLT SPRING WASHER COLLAR WASHER BUSHING WASHER BOLT LOWER ANCHOR BRACKET TOOTHED LOCK WASHER LOWER ANCHOR LOWER ANCHOR NUT D 7 16 20 UNF 32 N m 3 3 kgf m...

Page 2072: ...enger s seat remove the seat belt switch harness A Power seat Adjust the seat cushion to its maximum height and remove the harness Manual seat Remove the seat cushion mounting bolts B from the inner s...

Page 2073: ...lbf ft A NOTE Check the second row seat belts for damage and replace them if necessary 1 Remove the upper anchor cover A pull the lower anchor cover B back and remove the lower anchor bolt C 2 Remove...

Page 2074: ...WASHER RETRACTOR BOLT RETRACTOR TOOTHED LOCK WASHER 6 Install seat belt and retractor in the reverse order of removal and note these items Apply liquid thread lock to the anchor bolts before reinstal...

Page 2075: ...cushion 3 Remove the seat belt buckle A 4 Install the buckle in the reverse order of removal and apply liquid thread lock to the anchor bolt before reinstallation 1 Remove the second row seat through...

Page 2076: ...w seat belts for damage and replace them if necessary 1 Pull the lower anchor cover A back and remove the lower anchor bolt B 2 Remove these items Rear side trim panel see page 20 60 Rear pillar trim...

Page 2077: ...LOCK WASHER COLLAR SPRING WASHER RETRACTOR BOLT RETRACTOR TOOTHED LOCK WASHER 4 Install the seat belt and retractor in the reverse order of removal and note these items Apply liquid thread lock to the...

Page 2078: ...the metal plate C from the retractor cover D 2 Remove the webbing guide bolt A the retractor bolts B then remove the center shoulder seat belt C and retractor D 3 Install the seat belt and retractor...

Page 2079: ...Pull back the third row seat cushion mat as necessary see step 5 on page 20 126 2 Remove the center anchor bolts A from under the seat cushion 3 Remove the seat belt buckles A and center lap belt ton...

Page 2080: ...see page 23 19 03 04 models see page 23 20 and the precautions and procedures see page 23 21 before performing repairs or service 1 Before installing the retractor check that the seat belt can be pull...

Page 2081: ...ll the way out to engage the ALR The seat belt should retract but not extend This is normal 2 To disengage the ALR release the seat belt and allow it to fully retract then pull the seat belt out part...

Page 2082: ...rear trim panel C 2 Install the child seat tether anchor D Torque the bolt to 22 N m 2 2 kgf m 16 lbf ft and apply liquid thread lock to the threads of the anchor bolt s 1 Remove the third row child...

Page 2083: ...OUND SRS UNIT DATA LINK CONNECTOR DLC 16P SRS MAIN HARNESS to DRIVER S UNDER DASH FUSE RELAY BOX 2P CONNECTOR To RADIO REMOTE SWITCH DRIVER S SEAT BELT TENSIONER FRONT PASSENGER S SEAT BELT TENSIONER...

Page 2084: ...IMPACT SENSOR RIGHT FRONT IMPACT SENSOR FRONT PASSENGER S SIDE AIRBAG Replacement page 20 102 Initialization page 23 40 Replacement page 23 387 Replacement page 23 370 Disposal page 23 373 Replacement...

Page 2085: ...SIDE AIRBAG DRIVER S SEAT POSITION SENSOR SIDE AIRBAG CUTOFF INDICATOR Replacement page 20 102 Initialization page 23 41 Replacement page 23 387 Replacement page 23 370 Disposal page 23 373 Replaceme...

Page 2086: ...ter make sure its output is 10 mA 0 01A or less when switched to the lowest value in the ohmmeter range A tester with a higher output could cause accidental deployment and possible injury Do not put o...

Page 2087: ...ed airbag with the pad surface up Never put anything on the removed airbag To prevent damage to the airbag keep free from any oil grease detergent or water Store the removed airbag on a secure flat su...

Page 2088: ...sion in which the airbags or the side airbags did not deploy inspect for any damage or any deformation on the SRS unit front impact sensors and the side impact sensors If there is any damage replace t...

Page 2089: ...not get pinched or interfere with other parts Make sure all SRS ground locations are clean and grounds are securely fastened for optimum metal to metal contact Poor grounding can cause intermittent pr...

Page 2090: ...and press on the back of the sleeve side connector in the direction shown As the two connector halves are pressed together the sleeve A is pushed back by the pawl C Do not touch the sleeve 2 When the...

Page 2091: ...use the special tool if it is damaged Make sure to remove the special tool before reconnection When the SRS unit connector is disconnected a short circuit is created in the connector to prevent an ai...

Page 2092: ...e not to break the connector Seats with side airbags have a SIDE AIRBAG label on the seat back Because the component parts seat back cover cushion etc of seats with and without airbags are different m...

Page 2093: ...tch OFF disconnect the negative cable from the battery and wait at least 3 minutes before beginning the following procedures Before disconnecting the SRS unit 18P connector A from the SRS unit disconn...

Page 2094: ...st 3 minutes 2 Remove the access panel from the steering wheel then disconnect the driver s airbag 2P connector A and cable reel 2P connector B 3 Remove the glove box then disconnect the front passeng...

Page 2095: ...he seat belt tensioner connector disconnecting connectors from related devices or removing the dashboard or the steering column disconnect the airbag connectors or the side airbag connectors to preven...

Page 2096: ...the steering wheel then disconnect the driver s airbag 4P connector A from the cable reel 4P connector B 3 Remove the glove box then disconnect the front passenger s airbag 4P connector A from the SR...

Page 2097: ...IN HARNESS SRS MAIN HARNESS RIGHT SIDE WIRE HARNESS LEFT ENGINE COMPARTMENT WIRE HARNESS RIGHT ENGINE COMPARTMENT WIRE HARNESS SRS FLOOR HARNESS SRS FLOOR SUBHARNESS LEFT SIDE WIRE HARNESS RIGHT SIDE...

Page 2098: ...nutes 2 Remove the access panel from the steering wheel then disconnect the driver s airbag 4P connector A from the cable reel 4P connector B 3 Remove the glove box then disconnect the front passenger...

Page 2099: ...5 Remove the center pillar lower trim panel see page 20 58 Disconnect both seat belt tensioner 2P connectors A from the side wire harness 2P connectors B 6 Remove the center lower pocket see page 20...

Page 2100: ...ading and recording the DTC proceed with the troubleshooting procedure for this code Use only a digital multimeter to check the system If it s not a Honda multimeter make sure it s output is 10 mA 0 0...

Page 2101: ...the ignition switch is OFF 2 Connect the HDS to the DLC 16P B and follow the Tester s prompts in the SCS menu 3 Make sure the SCS line is grounded then turn the ignition switch ON II The SRS indicator...

Page 2102: ...ck period DTC 5 1 ON OFF ON OFF No DTC system is normal the indicator stays on Including the most recent problem up to three different DTCs can be indicated In case of a continuous failure the DTC wil...

Page 2103: ...is OFF 2 Connect the SCS service connector A to the MES connector 2P B Do not use a jumper wire 3 Turn the ignition switch ON II 4 The SRS indicator will come on for about 6 seconds and then go off Re...

Page 2104: ...mory as an intermittent failure and the SRS indicator will come on After checking the DTC troubleshoot as follows 1 Read the DTC 2 Erase the DTC memory 3 With the shift lever in neutral start the engi...

Page 2105: ...connector from the MES connector within 4 seconds after the SRS indicator went off 6 The SRS indicator comes on again Reconnect the SCS service connector to the MES connector within 4 seconds after th...

Page 2106: ...TE Make sure the front passenger s seat is dry Set the seat back in the normal position and make sure there is nothing on the front passenger s seat 1 Make sure the ignition switch is OFF 2 Connect th...

Page 2107: ...l you finish the next step after you start the drive the vehicle Do not expose the front passenger s seat to sudden temperature change 1 Position the front passenger s seat to the rear most position a...

Page 2108: ...the weight on the front passenger s seat 15 Drive the vehicle accelerate to 20 mph 36 km hr then stop on level ground 16 From the inspection menu select SEAT OUTPUT CHK The weight T1 of the front pass...

Page 2109: ...on procedures except test driving in the service bay Make sure the vehicle is on level ground Keep the A C and the heater off Do not touch the front passenger s seat until you drive the vehicle Do not...

Page 2110: ...t the tester from the DLC 11 Position the front passenger s seat to the rear most position adjust the recliner to the most forward position Do not move from these positions 12 Connect the Honda Diagno...

Page 2111: ...d by the HDS 19 Calculate the variance between the weight measured by the weight scale and by the tester using the formula provided If the variance is 8 6 lbs 3 9 kg or less If the variance is more th...

Page 2112: ...en All Data List Select SPS In the All Data List 6 Move the seat all the way forward and mark the seat with a line on the height outer cover where the front riser cover meets the seat riser using a pi...

Page 2113: ...tensioner see page 23 90 4 2 Increased resistance in front passenger s seat belt tensioner see page 23 90 4 3 Short to another wire or decreased resistance in front passenger s seat belt tensioner se...

Page 2114: ...esistance in driver s seat belt tensioner see page 23 119 3 3 Short to another wire or decreased resistance in driver s seat belt tensioner see page 23 122 3 4 Short to power in driver s seat belt ten...

Page 2115: ...g deployed 10 6 Driver s and front passenger s side airbags deployed 10 7 Seat belt tensioners and airbag s and driver s and front passenger s side airbags deployed 11 1 Open or increased resistance i...

Page 2116: ...s seat belt tensioner see page 23 224 21 8x Short to power in driver s seat belt tensioner see page 23 227 21 9x Short to ground in driver s seat belt tensioner see page 23 230 22 1x Open or increased...

Page 2117: ...page 23 276 43 3x 43 8x 43 Bx 44 1x No signal from the front passenger s side impact sensor see page 23 273 44 2x Internal failure of the front passenger s side impact sensor see page 23 276 44 3x 44...

Page 2118: ...ndicator stays on see page 23 319 91 1x Open in SRS indicator circuit see page 23 320 91 2x Short in SRS indicator circuit see page 23 323 92 1x Open in passenger airbag cutoff indicator see page 23 3...

Page 2119: ...Symptom Troubleshooting see page 23 349 SRS indicator stays on when in SCS menu method Symptom Troubleshooting see step 1 on page 23 353 Inability to retrieve DTCs with the HDS Retrieve the flash cod...

Page 2120: ...check If the indicator stays on it does not set a DTC Side airbag cutoff indicator is flashing Make sure nothing is on the front passenger s seat If the side airbag cutoff indicator stays on after th...

Page 2121: ...disconnected due to impact the voltage regulator and the back up power circuit respectively will keep voltage at a constant level 1 The impact sensor must activate and send electric signals to the mic...

Page 2122: ...d instantly inflate the driver s or the passenger s side airbag Only one side airbag will deploy during a side impact If the impact is on the passenger s side the passenger s side airbag will deploy e...

Page 2123: ...lectric signals to the microprocessor 2 The microprocessor must compute the signals and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF it sends the app...

Page 2124: ...In such cases the seat belt will provide sufficient protection and the supplemental protection offered by the airbag would be minimal The front passenger s weight sensors unit K is located under the...

Page 2125: ...firmly to secure the occupants in their seats The side airbag system also includes an Occupant Position Detection System OPDS This system consists of sensors G and a OPDS unit H in the front passenge...

Page 2126: ...low or power is disconnected due to the impact the voltage regulator and the back up power circuit respectively will keep voltage at a constant level 1 A front impact sensor must activate and send ele...

Page 2127: ...indicator does not come on or does not go off after 6 seconds or if it comes on while driving it indicates an abnormality in the system The system must be inspected and repaired as soon as possible Fo...

Page 2128: ...o 9 No 1 15A BLK YEL IG1 BAT IGNITION SWITCH WHT UNDER HOOD FUSE RELAY BOX No 42 50A No 41 120A BATTERY DRIVER S UNDER DASH FUSE RELAY BOX SRS INDICATOR CIRCUIT In the gauge assembly SRS INDICATOR BUL...

Page 2129: ...T YEL BLU 7 2 3 3 BLU 2 1 3 4 BLK YEL GRN BLU GRN 5 GRN G503 BLK BLU UNDER HOOD FUSE RELAY BOX IGNITION SWITCH IG1 HOT in ON II and START III UNDER DASH FUSE RELAY BOX DRIVER S AIRBAG FIRST INFLATOR D...

Page 2130: ...12 GRN BLK GRN RED BLK RED 11 10 2 1 1 2 SRS UNIT 1 2 12 7 BRN LT BLU 2 1 2 3 1 RED BLU G551 LEFT ENGINE COMPARTMENT WIRE HARNESS SRS MAIN HARNESS LEFT FRONT IMPACT SENSOR RIGHT FRONT IMPACT SENSOR R...

Page 2131: ...4 3 7 OPDS UNIT SRS UNIT BRN 16 27 RED 2 1 3 4 BLK YEL GRN BLU GRN 15 G503 BLK IGNITION SWITCH IG1 HOT in ON II and START III DASHBOARD WIRE HARNESS A DASHBOARD WIRE HARNESS B DASHBOARD WIRE HARNESS...

Page 2132: ...T GRN GRN YEL GRN GRN GRN YEL LT GRN GRN WHT RED WHT PNK 1 2 2 1 1 2 PNK RED WHT GRN WHT LT GRN GRN YEL GRN 25 26 19 20 21 22 BLU RED 2 1 SRS UNIT 2 1 12 7 1 2 2 3 1 RED BLU G551 DRIVER S SEAT WIRE HA...

Page 2133: ...and wait for 3 minutes 4 Disconnect the driver s airbag 2P connector from the cable reel 2P connector A 5 Connect the special tool 2 connector to the cable reel connector 6 Reconnect the battery negat...

Page 2134: ...rom the SRS unit Do not disconnect the special tool from the SRS main harness 2P connector 18 Check resistance between the No 1 terminal and the No 13 terminal of the SRS main harness 18P connector Th...

Page 2135: ...r s airbag 2P connector from the cable reel 2P connector A 5 Connect the special tool 2 connector to the cable reel 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read th...

Page 2136: ...ect the special tool from the SRS main harness 2P connector 18 Disconnect the SRS main harness 18P connector A from the SRS unit 19 Check resistance between the No 1 terminal and the No 13 terminal of...

Page 2137: ...from the cable reel 2P connector A 5 Connect the special tool 2 connector to the cable reel 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go...

Page 2138: ...harness 18P connector A from the SRS unit 18 Reconnect the battery negative cable 19 Turn the ignition switch ON II 20 Check for voltage between the No 1 terminal of the SRS main harness 18P connecto...

Page 2139: ...r 3 minutes 4 Disconnect the driver s airbag 2P connector from the cable reel 2P connector A 5 Connect the special tool 2 connector to the cable reel 2P connector 6 Reconnect the battery negative cabl...

Page 2140: ...and both seat belt tensioner 2P connectors B 17 Disconnect the SRS main harness 18P connector A from the SRS unit 18 Check resistance between the No 1 terminal of the SRS main harness 18P connector an...

Page 2141: ...OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 2P connector from the SRS main harness 2P connector A 5 Connect the special tool 2 connector...

Page 2142: ...main harness replace the SRS main harness 1 Erase the DTC memory see page 23 38 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Go to s...

Page 2143: ...0 Disconnect the driver s airbag 2P connector A and both seat belt tensioner 2P connectors B 11 Disconnect the special tool 2 from the SRS main harness 2P connector 12 Disconnect the SRS main harness...

Page 2144: ...onnect the front passenger s airbag 2P connector from the SRS main harness 2P connector A 5 Connect the special tool 2 connector to the SRS main harness 2P connector 6 Reconnect the battery negative c...

Page 2145: ...Short to power in the SRS main harness replace the SRS main harness 1 Erase the DTC memory see page 23 38 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 second...

Page 2146: ...2P connector A and both seat belt tensioner 2P connectors B and disconnect the special tool from the SRS main harness 2P connector 11 Disconnect the SRS main harness 18P connector A from the SRS unit...

Page 2147: ...ct the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Open or increased re...

Page 2148: ...ol from the left side wire harness 2P connector 18 Check resistance between the No 4 terminal and the No 11 terminal of the SRS main harness 18P connector There should be 2 0 3 0 Faulty SRS unit or po...

Page 2149: ...onnector A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Sh...

Page 2150: ...harness 18P connector A from the SRS unit 19 Check resistance between the No 4 terminal and the No 11 terminal of the SRS main harness 18P connector There should be an open circuit or at least 1 M Fau...

Page 2151: ...connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Short to power in the driver s seat belt...

Page 2152: ...nect the battery negative cable 19 Turn the ignition switch ON II 20 Check for voltage between the No 4 terminal of the SRS main harness 18P connector and body ground and between the No 11 terminal an...

Page 2153: ...nnector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Short to ground in the driver s seat belt te...

Page 2154: ...rness 2P connector 18 Check resistance between the No 4 terminal of the SRS main harness 18P connector and body ground and between the No 11 terminal and body ground There should be an open circuit or...

Page 2155: ...ight side wire harness 2P connector A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC se...

Page 2156: ...SRS unit Do not disconnect the special tool from the right side wire harness 2P connector 18 Check resistance between the No 5 terminal and the No 12 terminal of the SRS main harness 18P connector Th...

Page 2157: ...ctor A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Short...

Page 2158: ...8P connector A from the SRS unit 19 Check resistance between the No 5 terminal and the No 12 terminal of the SRS main harness 18P connector There should be an open circuit or at least 1 M Faulty SRS u...

Page 2159: ...wire harness 2P connector A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23...

Page 2160: ...the SRS main harness 2P connector 18 Reconnect the battery negative cable 19 Turn the ignition switch ON II 20 Check for voltage between the No 5 terminal of the SRS main harness 18P connector and bod...

Page 2161: ...ial tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Short to ground in the front p...

Page 2162: ...2P connector 18 Check resistance between the No 5 terminal of the SRS main harness 18P connector and body ground and between the No 12 terminal and body ground There should be an open circuit or at l...

Page 2163: ...place the battery before troubleshooting the SRS If the battery system voltage is now OK ask the customer if the battery ever went dead 1 Erase the DTC memory see page 23 38 2 Turn the ignition switch...

Page 2164: ...n the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector from the cable reel 4P connector A 5 Connect the special tool 2 con...

Page 2165: ...l from the cable reel 4P connector 13 Check resistance between the No 7 and the No 16 terminals and between the No 6 and the No 15 terminals of SRS unit connector A 18P There should be 2 0 3 0 Faulty...

Page 2166: ...ls and between the No 3 and the No 4 terminals of the SRS main harness 28P connector There should be 2 0 3 0 Open or increased resistance in the SRS floor harness replace the SRS floor harness Open or...

Page 2167: ...termittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector from the cable reel 4P conn...

Page 2168: ...d the No 15 terminals of SRS unit connector A 18P There should be an open circuit or at least 1 M Faulty SRS unit replace the SRS unit see page 23 382 Go to step 15 15 Disconnect the cable reel from t...

Page 2169: ...S floor harness 28P connector C851 17 Check resistance between the No 9 and the No 10 terminals and between the No 3 and the No 4 terminals of the SRS main harness 28P connector There should be an ope...

Page 2170: ...ry negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector from the cable reel 4P connector A 5 Connect the special tool 2 connectors to the cable reel 4P connector 6 Recon...

Page 2171: ...nd and the No 15 terminal and body ground There should be 0 5 V or less Faulty SRS unit replace the SRS unit see page 23 382 Go to step 17 17 Turn the ignition switch OFF 18 Disconnect the cable reel...

Page 2172: ...Turn the ignition switch ON II 24 Check for voltage between the No 9 terminal of the SRS main harness 28P connector and body ground the No 10 terminal and body ground the No 3 terminal and body ground...

Page 2173: ...isconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector from the cable reel 4P connector A 5 Connect the special tool 2 connectors to the cable reel 4...

Page 2174: ...ere should be an open circuit or at least 1 M Faulty SRS unit replace the SRS unit see page 23 382 Go to step 15 15 Disconnect the cable reel from the SRS main harness 16 Check resistance between the...

Page 2175: ...C851 18 Check resistance between the No 9 terminal of the SRS main harness 28P connector and body ground the No 10 terminal and body ground the No 3 terminal and body ground and No 4 terminal and body...

Page 2176: ...ive cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness 4P connector A 5 Connect the special tool 2 connectors to the SRS main harness 4P conn...

Page 2177: ...ween the No 4 and No 13 terminals and between the No 5 and No 14 terminals of SRS unit connector A 18P There should be 2 0 3 0 Faulty SRS unit or poor contact at the SRS unit connector A 18P Check the...

Page 2178: ...ct the battery negative cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness 4P connector A 5 Connect the special tool 2 connectors to the SRS...

Page 2179: ...t least 1 M Faulty SRS unit replace the SRS unit see page 23 382 Go to step 15 15 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P connector C851 16 Check resistance betw...

Page 2180: ...ive cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness 4P connector A 5 Connect the special tool 2 connectors to the SRS main harness 4P conn...

Page 2181: ...0 5 V or less Faulty SRS unit replace the SRS unit see page 23 382 Go to step 17 17 Turn the ignition switch OFF 18 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P conne...

Page 2182: ...ive cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness 4P connector A 5 Connect the special tool 2 connectors to the SRS main harness 4P conn...

Page 2183: ...There should be an open circuit or at least 1 M Faulty SRS unit replace the SRS unit see page 23 382 Go to step 15 15 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P con...

Page 2184: ...r A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Open or i...

Page 2185: ...from the SRS unit Do not disconnect the special tool from the left side wire harness 2P connector 18 Check resistance between the No 8 terminal and the No 17 terminal of SRS unit connector A 18P Ther...

Page 2186: ...20 Check resistance between the No 5 and the No 14 terminals of the SRS main harness 28P connector There should be 2 0 3 0 Open or increased resistance in the SRS floor harness replace the SRS floor h...

Page 2187: ...nnector from the left side wire harness 2P connector A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8...

Page 2188: ...nect SRS unit connector A 18P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 8 and the No 17 terminals of the SRS unit conne...

Page 2189: ...harness 28P connector C851 21 Check resistance between the No 5 and the No 14 terminals of the SRS main harness 28P connector There should be an open circuit or at least 1 M Short in the SRS floor har...

Page 2190: ...onnector A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 35 Go to step 9 Sh...

Page 2191: ...from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Reconnect the battery negative cable 20 Turn the ignition switch ON II 21 Check for voltage between the No 8...

Page 2192: ...gnition switch ON II 25 Check for voltage between the No 5 terminal of the SRS main harness 28P connector and body ground and between the No 14 terminal and body ground There should be 0 5 V or less S...

Page 2193: ...e wire harness 2P connector A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23...

Page 2194: ...r A 18P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 8 terminal of SRS unit connector A 18P and body ground and between th...

Page 2195: ...S floor harness 28P connector C851 21 Check resistance between the No 5 terminal of the SRS main harness 28P connector and body ground between the No 14 terminal and body ground There should be an ope...

Page 2196: ...from the right side wire harness 2P connector A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read...

Page 2197: ...onnector C 17 Disconnect SRS unit connector A 18P from the SRS unit Do not disconnect the special tool from the SRS main harness 2P connector 18 Check resistance between the No 9 and the No 18 termina...

Page 2198: ...20 Check resistance between the No 6 and the No 15 terminals of the SRS main harness 28P connector There should be 2 0 3 0 Open or increased resistance in the SRS floor harness replace the SRS floor h...

Page 2199: ...or from the right side wire harness 2P connector A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Re...

Page 2200: ...S unit connector A 18P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 9 terminal and the No 18 terminals of SRS unit connect...

Page 2201: ...harness 28P connector C851 21 Check resistance between the No 6 and the No 15 terminals of the SRS main harness 28P connector There should be an open circuit or at least 1 M Short in the SRS floor har...

Page 2202: ...from the right side wire harness 2P connector A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read...

Page 2203: ...C 17 Disconnect SRS unit connector A 18P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Reconnect the battery negative cable 20 Turn the ignition switch ON...

Page 2204: ...gnition switch ON II 25 Check for voltage between the No 6 terminal of the SRS main harness 28P connector and body ground and between the No 15 terminal and body ground There should be 0 5 V or less S...

Page 2205: ...wire harness 2P connector A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23...

Page 2206: ...18P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 9 terminal of SRS unit connector A 18P and body ground and between the No...

Page 2207: ...floor harness 28P connector C851 21 Check resistance between the No 6 terminal of the SRS main harness 28P connector and body ground and between the No 15 terminal and body ground There should be an o...

Page 2208: ...system or replace the battery before troubleshooting the SRS If the battery system voltage is now OK ask the customer if the battery ever went dead 1 Erase the DTC memory see page 23 38 2 Turn the ig...

Page 2209: ...en goes off Replace the driver s side impact sensor see page 23 385 Intermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page 23 39 1 Erase the DTC memory see...

Page 2210: ...4 Turn the ignition switch OFF 5 Disconnect the left side wire harness 3P connector A from the driver s seat belt buckle switch 3P connector B 6 Buckle the driver s seat belt Check resistance between...

Page 2211: ...t buckle assembly and clear the DTC 8 Check resistance between the No 1 terminal of the left side wire harness connector and body ground There should be 0 1 Go to step 9 Open in the left side wire har...

Page 2212: ...tor and body ground There should be an open circuit or at least 1 M Go to step 13 Go to step 17 13 Check resistance between the No 8 terminal of SRS unit connector C 8P and the No 3 terminal of the le...

Page 2213: ...SRS floor harness Short to ground in the left side wire harness or dashboard wire harness replace the faulty harness 17 Disconnect the SRS main harness 8P connector A from the dashboard wire harness 8...

Page 2214: ...S main harness or SRS floor harness replace the SRS floor harness If the problem is still present replace the SRS main harness 21 Disconnect the SRS main harness 8P connector A from the dashboard wire...

Page 2215: ...ilures see page 23 39 4 Turn the ignition switch OFF 5 Disconnect the front passenger s seat belt buckle switch 3P connector A from the floor wire harness 3P connector B 6 Buckle the front passenger s...

Page 2216: ...or at least 1 M Go to step 8 Replace the front passenger s seat belt buckle assembly and clear the DTC 8 Check resistance between the No 1 terminal of the right side wire harness 3P connector and body...

Page 2217: ...rness 3P connector and body ground There should be an open circuit or at least 1 M Go to step 13 Go to step 17 13 Check resistance between the No 7 terminal of SRS unit connector C 8P and the No 3 ter...

Page 2218: ...rt to ground in the right side wire harness or dashboard wire harness replace the faulty harness 17 Disconnect the SRS main harness 8P connector A from the dashboard wire harness 8P connector C503 18...

Page 2219: ...rness or dashboard wire harness replace the faulty harness Open in the SRS main harness or SRS floor harness replace the SRS floor harness 21 Disconnect the SRS main harness 8P connector A from the da...

Page 2220: ...and the SRS unit and between the left engine compartment wire harness 2P connector and the left front sensor see page 23 19 and at the 4P connector between the SRS main harness and the SRS floor harne...

Page 2221: ...tween the No 10 and No 11 terminals of SRS unit connector A 18P There should be an open circuit or at least 1 M Go to step 11 Go to step 17 11 Reconnect the battery negative cable 12 Turn the ignition...

Page 2222: ...nt sensor if the problem is still present replace the SRS unit see page 23 382 Go to step 23 17 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P connector C851 18 Check r...

Page 2223: ...he SRS floor harness replace the SRS floor harness Short to power in the left engine compartment wire harness or SRS main harness replace the faulty harness 23 Disconnect the SRS main harness 28P conn...

Page 2224: ...nnector A 18P and the SRS unit and between the right engine compartment wire harness 2P connector and the right front impact sensor see page 23 19 and at the 4P connector between the SRS main harness...

Page 2225: ...nce between the No 1 and No 12 terminals of SRS unit connector A 18P There should be an open circuit or at least 1 M Go to step 11 Go to step 17 11 Reconnect the battery negative cable 12 Turn the ign...

Page 2226: ...sensor if the problem is still present replace the SRS unit see page 23 382 Go to step 23 17 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P connector C851 18 Check res...

Page 2227: ...e SRS floor harness replace the SRS floor harness Short to power in the right engine compartment wire harness or SRS main harness replace the faulty harness 23 Disconnect the SRS main harness 28P conn...

Page 2228: ...39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag B 5 Connect the spec...

Page 2229: ...nit check the connection if the connection is OK replace the SRS unit see page 23 382 Go to step 13 13 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852...

Page 2230: ...tch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag B 5 Connect the special tool 2 connector to th...

Page 2231: ...see page 23 382 Go to step 14 14 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 15 Check resistance between the No 21 and No 22 terminals of the SRS...

Page 2232: ...39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag B 5 Connect the spec...

Page 2233: ...step 14 14 Turn the ignition switch OFF 15 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 16 Turn the ignition switch ON II 17 Check for voltage betw...

Page 2234: ...39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag B 5 Connect the spec...

Page 2235: ...23 382 Go to step 13 13 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 14 Check resistance between the No 22 and No 17 terminals of the SRS floor su...

Page 2236: ...urn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag B 5 Connect the...

Page 2237: ...unit check the connection if the connector is OK replace the SRS unit see page 23 382 Go to step 13 13 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852...

Page 2238: ...F Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag B 5 Connect the special tool 2 connector t...

Page 2239: ...see page 23 382 Go to step 14 14 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 15 Check resistance between the No 23 and No 24 terminals of the SRS...

Page 2240: ...urn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag B 5 Connect the...

Page 2241: ...step 14 14 Turn the ignition switch OFF 15 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 16 Turn the ignition switch ON II 17 Check for voltage betw...

Page 2242: ...urn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag B 5 Connect the...

Page 2243: ...3 382 Go to step 13 13 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 14 Check resistance between the No 17 and No 23 terminals of the SRS floor subh...

Page 2244: ...Troubleshooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Check the connection between the left side wire harn...

Page 2245: ...23 385 If the problem is still present replace the SRS unit see page 23 382 Go to step 10 10 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 11 Check...

Page 2246: ...ittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Discon...

Page 2247: ...e impact sensor see page 23 385 If the problem is still present replace the SRS unit see page 23 382 Go to step 11 9 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P...

Page 2248: ...12 Check resistance between the No 18 and No 17 terminals of the SRS floor subharness 28P connector There should be an open circuit or at least 1 M Short in the SRS floor harness replace the SRS floo...

Page 2249: ...3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Check the connection between the right side wire harness 2P connector and the front passenger s side impa...

Page 2250: ...If the problem is still present replace the SRS unit see page 23 382 Go to step 10 10 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C852 11 Check resista...

Page 2251: ...Go to step 3 Intermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for...

Page 2252: ...nsor see page 23 385 If the problem is still present replace the SRS unit see page 23 382 Go to step 11 9 Disconnect the SRS floor subharness 28P connector A from the SRS floor harness 28P connector C...

Page 2253: ...connector C852 12 Check resistance between the No 28 and No 27 terminals of the SRS floor subharness 28P connector There should be an open circuit or at least 1 M Short in the SRS floor harness repla...

Page 2254: ...se in the under dash fuse relay box Go to step 6 Go to step 9 6 Disconnect OPDS unit harness 8P connector D 8P from the OPDS unit A 7 Turn the ignition switch ON II 8 Check for voltage between the No...

Page 2255: ...age 23 387 Short to ground in the No 11 10A circuit 16 Turn the ignition switch OFF 17 Check resistance between the No 8 terminal of OPDS unit harness connector D 8P and body ground There should be 0...

Page 2256: ...tep 27 22 Check resistance between the No 3 terminal of SRS unit connector B 18P and the No 7 terminal of the OPDS unit harness connector D 8P There should be 0 1 0 Go to step 23 Go to step 31 23 Disc...

Page 2257: ...oblem is still present replace the SRS unit see page 23 382 Go to step 35 27 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P connector C851 28 Check resistance between t...

Page 2258: ...rness replace the SRS main harness Short in the dashboard wire harness right side wire harness or OPDS unit harness replace the faulty harness 31 Disconnect the SRS main harness 28P connector A from t...

Page 2259: ...ess replace the SRS main harness Open in the dashboard wire harness right side wire harness or OPDS unit harness replace the faulty harness 35 Turn the ignition switch OFF 36 Disconnect the SRS main h...

Page 2260: ...gnition switch ON II 42 Check for voltage between the No 1 terminal of the dashboard wire harness 8P connector and body ground There should be 0 5 V or less Short to power in the SRS main harness repl...

Page 2261: ...ger s seat 4 Turn the ignition switch ON II and check that the side airbag cutoff indicator comes on Go to step 5 Go to step 6 5 Make sure the side airbag cutoff indicator comes on for 5 seconds and t...

Page 2262: ...uld be 0 5 V or less Faulty OPDS unit replace the OPDS unit see page 23 387 Go to step 15 15 Turn the ignition switch OFF 16 Disconnect gauge assembly connector A 14P from the gauge assembly see page...

Page 2263: ...he faulty harness Short to power in the OPDS unit harness replace the OPDS unit harness 23 Turn the ignition switch OFF 24 Backprobe the No 4 terminal of gauge assembly connector A 14P Do not disconne...

Page 2264: ...arness Poor contact at gauge assembly connector A 14P or an open in the dashboard wire harness or right side wire harness Check gauge assembly connector A 14P if the connections are OK replace the fau...

Page 2265: ...gauge assembly connector A 14P from the gauge assembly see page 22 100 40 Check resistance between the No 4 terminal of gauge assembly connector A 14P and body ground There should an open circuit or...

Page 2266: ...erase the DTC operate the device near the seat back and recheck for DTCs If DTC 15 3 is reset erase it and do not use the device near the seat back 3 Check the connection at the OPDS sensor harness co...

Page 2267: ...rmittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector from the cable reel A 5 Conne...

Page 2268: ...ge 23 382 Go to step 13 13 Disconnect the SRS floor harness 28P connector A from SRS main harness 28P connector C851 14 Check resistance between the No 9 and No 10 terminals of the SRS floor harness 2...

Page 2269: ...ort canceler 070AZ SAA0100 1 Erase the DTC memory see page 23 39 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Go to step 3 Intermitt...

Page 2270: ...isconnect the SRS inflator simulator from SRS simulator lead F 12 Check resistance between the terminals of SRS simulator lead F There should be an open circuit or at least 1 M Go to step 13 Replace t...

Page 2271: ...d No 8 terminals or the No 1 and No 2 terminals of SRS unit connector A 28P see page 23 26 17 Check resistance between the No 9 and No 10 terminals of the SRS floor harness 28P connector C851 and betw...

Page 2272: ...39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector from the cable reel A 5 Connect the special tool 2 connect...

Page 2273: ...V or less Faulty SRS unit replace the SRS unit see page 23 384 Go to step 15 15 Turn the ignition switch OFF 16 Disconnect the SRS main harness 4P connector from the cable reel 17 Turn the ignition sw...

Page 2274: ...or C851 21 Turn the ignition switch ON II 22 Check for voltage between the No 9 terminal of SRS floor harness 28P connector and body ground the No 10 terminal and body ground the No 3 terminal and bod...

Page 2275: ...e Go to Troubleshooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector f...

Page 2276: ...at least 1 M Faulty SRS unit replace the SRS unit see page 23 384 Go to step 13 13 Disconnect the SRS main harness 4P connector from the cable reel 4P connector 14 Check resistance between each termi...

Page 2277: ...onnector C851 16 Check resistance between the No 9 terminal of the SRS floor harness 28P connector and body ground the No 10 terminal and body ground the No 3 terminal and body ground and No 4 termina...

Page 2278: ...23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness A 5 Connect the spec...

Page 2279: ...replace the SRS unit see page 23 384 Go to step 13 13 Disconnect the SRS floor harness 28P connector A from SRS main harness connector C851 14 Check resistance between the No 7 and No 8 terminals and...

Page 2280: ...page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness A 5 Connect the...

Page 2281: ...23 384 Go to step 14 14 Disconnect the SRS floor harness 28P connector A from SRS main harness connector C851 15 Check resistance between the No 7 and No 8 terminals and between the No 1 and No 2 ter...

Page 2282: ...e ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the dashboard wire harness A 5 Connect the special tool 2...

Page 2283: ...onnect the SRS floor harness 28P connector A from SRS main harness connector C851 17 Turn the ignition switch ON II 18 Check for voltage between the No 7 terminal of the SRS floor harness 28P connecto...

Page 2284: ...Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the front passenger s airbag 4P connector from the SRS main harness A 5...

Page 2285: ...see page 23 384 Go to step 13 13 Disconnect the SRS floor harness 28P connector A from SRS main harness connector C851 14 Check resistance between the No 7 terminal of the SRS floor harness 28P connec...

Page 2286: ...ire harness A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 38 Go to step 9...

Page 2287: ...it Do not disconnect the special tool from the SRS main harness 2P connector 18 Check resistance between the No 1 terminal and the No 2 terminal of SRS unit connector B 28P There should be 2 0 3 0 Fau...

Page 2288: ...C851 20 Check resistance between the No 5 and No 14 terminals of the SRS main harness 28P connector There should be 2 0 3 0 Open or increased resistance in the SRS floor harness replace the SRS floor...

Page 2289: ...t belt tensioner 2P connector from the left side wire harness A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC...

Page 2290: ...P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 1 terminal and No 2 terminals of SRS unit connector B 28P There should be a...

Page 2291: ...SRS main harness connector C851 21 Check resistance between the No 5 and No 14 terminals of the SRS main harness 28P connector There should be an open circuit or at least 1 M Short in the SRS floor h...

Page 2292: ...side wire harness A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC see page 23 38 Go to...

Page 2293: ...ect the special tool from the SRS main harness 2P connector 19 Reconnect the battery negative cable 20 Turn the ignition switch ON II 21 Check for voltage between the No 1 terminal of SRS unit connect...

Page 2294: ...he ignition switch ON II 25 Check for voltage between the No 5 terminal of the SRS main harness 28P connector and body ground and between the No 14 terminal and body ground There should be 0 5 V or le...

Page 2295: ...ctor from the left side wire harness A 5 Connect the special tool 2 connector to the left side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC se...

Page 2296: ...Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 1 terminal of SRS unit connector B 28P and body ground and between the No 2 terminal and body gro...

Page 2297: ...the SRS main harness connector C851 21 Check resistance between the No 5 terminal of the SRS main harness 28P connector and body ground and between the No 14 terminal and body ground There should be...

Page 2298: ...tensioner 2P connector from the right side wire harness A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memo...

Page 2299: ...RS unit connector B 28P from the SRS unit Do not disconnect the special tool from the SRS main harness 2P connector 18 Check resistance between the No 3 and No 4 terminals of SRS unit connector B 28P...

Page 2300: ...C851 20 Check resistance between the No 6 and No 15 terminals of the SRS main harness 28P connector There should be 2 0 3 0 Open or increased resistance in the SRS floor harness replace the SRS floor...

Page 2301: ...t tensioner 2P connector from the right side wire harness A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC me...

Page 2302: ...P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 3 and No 4 terminals of SRS unit connector B 28P There should be an open ci...

Page 2303: ...SRS main harness connector C851 21 Check resistance between the No 6 and No 15 terminals of the SRS main harness 28P connector There should be an open circuit or at least 1 M Short in the SRS floor h...

Page 2304: ...at belt tensioner 2P connector from the right side wire harness A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the...

Page 2305: ...nnector B 28P from the SRS unit 18 Disconnect the special tool from the SRS main harness 2P connector 19 Reconnect the battery negative cable 20 Turn the ignition switch ON II 21 Check for voltage bet...

Page 2306: ...he ignition switch ON II 25 Check for voltage between the No 6 terminal of the SRS main harness 28P connector and body ground and between the No 15 terminal and body ground There should be 0 5 V or le...

Page 2307: ...or from the right side wire harness A 5 Connect the special tool 2 connector to the right side wire harness 2P connector 6 Reconnect the battery negative cable 7 Erase the DTC memory 8 Read the DTC se...

Page 2308: ...connect the special tool from the SRS main harness 2P connector 19 Check resistance between the No 3 terminal of SRS unit connector B 28P and body ground and between the No 4 terminal and body ground...

Page 2309: ...he SRS main harness 28P connector C851 21 Check resistance between the No 6 terminal of the SRS main harness 28P connector and body ground and between the No 15 terminal and body ground There should b...

Page 2310: ...ative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag 5 Connect the special tool 2 connector to the left side wire harness 2P connecto...

Page 2311: ...Check the connection if the connection is OK replace the SRS unit see page 23 384 Go to step 14 14 Disconnect the SRS floor harness 28P connector A from SRS floor subharness C852 15 Check resistance b...

Page 2312: ...res see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag 5 Co...

Page 2313: ...lead E There should be an open circuit or at least 1 M Faulty SRS unit replace the SRS unit see page 23 384 Go to step 15 15 Disconnect the SRS floor harness 28P connector A from SRS floor subharness...

Page 2314: ...on switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag 5 Connect the special tool 2 connector t...

Page 2315: ...ce the SRS unit see page 23 384 Go to step 16 16 Turn the ignition switch OFF 17 Disconnect the SRS floor harness 28P connector A from the SRS floor subharness C852 18 Turn the ignition switch ON II 1...

Page 2316: ...on switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the left side wire harness 2P connector A from the driver s side airbag 5 Connect the special tool 2 connector t...

Page 2317: ...S unit see page 23 384 Go to step 14 14 Disconnect the SRS floor harness 28P connector A from the SRS floor subharness C852 15 Check resistance between the No 21 terminal of the SRS floor harness 28P...

Page 2318: ...and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag 5 Connect the special tool 2 connector to the right side wire harness 2P connecto...

Page 2319: ...Check the connection if the connection is OK replace the SRS unit see page 23 384 Go to step 14 14 Disconnect the SRS floor harness 28P connector A from SRS floor subharness C852 15 Check resistance...

Page 2320: ...3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag 5 Connect th...

Page 2321: ...ead E There should be an open circuit or at least 1 M Faulty SRS unit replace the SRS unit see page 23 384 Go to step 15 15 Disconnect the SRS floor harness 28P connector A from the SRS floor subharne...

Page 2322: ...OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag 5 Connect the special tool 2 connector t...

Page 2323: ...ce the SRS unit see page 23 384 Go to step 16 16 Turn the ignition switch OFF 17 Disconnect the SRS floor harness 28P connector A from SRS floor subharness C852 18 Turn the ignition switch ON II 19 Ch...

Page 2324: ...OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the right side wire harness 2P connector A from the front passenger s side airbag 5 Connect the special tool 2 connector t...

Page 2325: ...the SRS unit see page 23 384 Go to step 14 14 Disconnect the SRS floor harness 28P connector A from SRS floor subharness C852 15 Check resistance between the No 23 terminal of the SRS floor harness 2...

Page 2326: ...ion switch OFF Check the connections between SRS unit connector A 28P and the SRS unit and between the left engine compartment wire harness 2P connector and the left front sensor see page 23 20 and at...

Page 2327: ...e No 15 and No 27 terminals of SRS unit connector A 28P There should be an open circuit or at least 1 M Go to step 11 Go to step 17 11 Reconnect the battery negative cable 12 Turn the ignition switch...

Page 2328: ...ace the left front impact sensor if the problem is still present replace the SRS unit see page 23 384 Go to step 23 17 Disconnect the SRS floor harness 28P connector A from SRS main harness connector...

Page 2329: ...or less Short to power in the engine compartment left wire harness or SRS main harness replace the faulty harness Short to power in the SRS floor harness replace the SRS floor harness 23 Disconnect t...

Page 2330: ...n switch OFF Check the connections between SRS unit connector A 28P and the SRS unit between the engine compartment right wire harness 2P connector and the right front impact sensor see page 23 20 and...

Page 2331: ...o 16 and No 28 terminals of SRS unit connector A 28P There should be an open circuit or at least 1 M Go to step 11 Go to step 17 11 Reconnect the battery negative cable 12 Turn the ignition switch ON...

Page 2332: ...the right front impact sensor if the problem is still present replace the SRS unit see page 23 384 Go to step 23 17 Disconnect the SRS main harness 28P connector A from SRS floor harness connector C85...

Page 2333: ...ess Short to power in the engine compartment right wire harness or SRS main harness replace the faulty harness Short to power in the SRS floor harness replace the SRS floor harness 23 Disconnect the S...

Page 2334: ...memory see page 23 39 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Replace the left front impact sensor see page 23 388 Intermittent...

Page 2335: ...this time Go to Troubleshooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Check the connection between the left...

Page 2336: ...from the SRS unit 10 Check resistance between the No 19 and No 20 terminals of SRS unit connector B 28P There should be 0 1 0 Faulty driver s side impact sensor or SRS unit replace the driver s side...

Page 2337: ...floor subharness 28P connector C852 12 Check resistance between the No 18 and No 17 terminals of the SRS floor subharness 28P connector There should be 0 1 0 Open in the SRS floor harness replace the...

Page 2338: ...tent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Check the connection between the right side wire harness 2P connector and the...

Page 2339: ...ire harness A 9 Disconnect SRS unit connector B 28P from the SRS unit 10 Check resistance between the No 25 and No 26 terminals of SRS unit connector B 28P There should be 0 1 0 Faulty front passenger...

Page 2340: ...8P connector C852 12 Check resistance between the No 28 and No 27 terminals of the SRS floor subharness 28P connector There should be 0 1 0 Open in the SRS floor harness replace the SRS floor harness...

Page 2341: ...Erase the DTC memory see page 23 39 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Replace the driver s side impact sensor see page 2...

Page 2342: ...e SRS indicator comes on for about 6 seconds and then goes off Replace the SRS unit see page 23 384 Intermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page...

Page 2343: ...2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Replace the SRS unit see page 23 384 Intermittent failure system is OK at this time Go...

Page 2344: ...e SRS indicator comes on for about 6 seconds and then goes off Replace the SRS unit see page 23 384 Intermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page...

Page 2345: ...ory see page 23 39 2 Turn the ignition switch ON II and check that the SRS indicator comes on for about 6 seconds and then goes off Replace the SRS unit see page 23 384 Intermittent failure system is...

Page 2346: ...e SRS indicator comes on for about 6 seconds and then goes off Replace the SRS unit see page 23 384 Intermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page...

Page 2347: ...11 D7 11 E2 11 E4 11 F1 11 F2 11 F3 11 F4 11 23 282 SRS DTC Troubleshooting cont d Airbags Side airbags and or Seat Belt Tensioners Deployed The SRS unit must be replaced after any airbags and or ten...

Page 2348: ...ntermittent Failures see page 23 39 4 Turn the ignition switch OFF 5 Disconnect the driver s seat belt buckle switch 3P connector A 6 Buckle the driver s seat belt Check resistance between the No 1 an...

Page 2349: ...step 8 Replace the driver s seat belt buckle assembly then clear the DTC 8 Check resistance between the No 1 terminal of the driver s seat wire harness with power seat or left side wire harness withou...

Page 2350: ...ess A SRS main harness or SRS floor harness replace the faulty harness 13 Check resistance between the No 11 terminal of SRS unit connector B 28P and the No 2 terminal of the driver s seat wire harnes...

Page 2351: ...o Troubleshooting Intermittent Failures see page 23 39 4 Turn the ignition switch OFF 5 Disconnect the driver s seat belt buckle switch 3P connector A 6 Buckle the driver s seat belt Check resistance...

Page 2352: ...circuit or at least 1 M Go to step 8 Replace the driver s seat belt buckle assembly then clear the DTC 8 Disconnect the negative cable from the battery 9 Disconnect both seat belt tensioner 2P connec...

Page 2353: ...e driver s seat wire harness with power seat left side wire harness dashboard wire harness A SRS main harness SRS floor harness or multiplex control unit or gauge assembly replace the faulty harness o...

Page 2354: ...ntermittent Failures see page 23 39 4 Turn the ignition switch OFF 5 Disconnect the front passenger s seat belt buckle switch 3P connector A 6 Buckle the front passenger s seat belt Check resistance b...

Page 2355: ...step 8 Replace the front passenger s seat belt buckle assembly then clear the DTC 8 Check resistance between the No 1 terminal of the passenger s seat wire harness with seat heater or right side wire...

Page 2356: ...r 3P connector There should be 0 1 Go to step 13 Open in the passenger s seat wire harness with seat heater right side wire harness dashboard wire harness A SRS main harness or SRS floor harness repla...

Page 2357: ...to Troubleshooting Intermittent Failures see page 23 39 4 Turn the ignition switch OFF 5 Disconnect the front passenger s seat belt buckle switch 3P connector A 6 Buckle the front passenger s seat bel...

Page 2358: ...0 1 Check resistance between the No 1 and No 3 terminals of the same connector There should be an open circuit or at least 1 M Go to step 8 Replace the front passenger s seat belt buckle assembly then...

Page 2359: ...east 1 M Go to step 12 Short to ground in the passenger s seat wire harness with seat heater right side wire harness dashboard wire harness A SRS main harness or SRS floor harness replace the faulty h...

Page 2360: ...ry 5 Read the DTC see page 23 38 Go to step 6 Repair the poor connections and retest If DTC 71 1x is still present go to step 6 6 Turn the ignition switch OFF Disconnect the battery negative cable and...

Page 2361: ...r SRS unit replace the driver s seat position sensor see page 23 392 If the problem is still present replace the SRS unit see page 23 384 Go to step 13 13 Disconnect SRS floor harness 28P connector A...

Page 2362: ...at wire harness with power seat or the left side wire harness 2P connector C559 from the driver s seat position sensor subharness without power seat 18 Check resistance between the No 5 and No 12 term...

Page 2363: ...n switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect the driver s airbag 4P connector A from the cable reel 5 Disconnect the driver s seat wire harness 2P connector w...

Page 2364: ...al of SRS unit connector B 28P and body ground and the No 28 terminal and body ground There should an open circuit or at least 1 M Faulty SRS unit or poor contact at SRS unit connector B 28P and the S...

Page 2365: ...in the SRS floor subharness replace the SRS floor subharness Go to step 17 17 Disconnect left side wire harness 12P connector C 552 from driver s seat wire harness with power seat or left side wire h...

Page 2366: ...step 8 Repair the poor connections and retest If DTC 81 61 or 81 62 is still present go to step 8 8 Turn the ignition switch OFF 9 Check the No 11 10A fuse in the driver s under dash fuse relay box Go...

Page 2367: ...step 19 Open in the BLK wire of the right side wire harness check for poor ground connection at G851 If the connection is OK replace the right side wire harness 19 Turn the ignition switch OFF Disconn...

Page 2368: ...t 1 M Go to step 23 Go to step 30 23 Check resistance between the No 27 terminal of SRS unit connector B 28P and the No 5 terminal should be 0 1 0 Faulty front passenger s weight sensors unit or SRS u...

Page 2369: ...from dashboard wire harness A 27 Check resistance between the No 27 terminal of SRS unit connector B 28P and the No 1 terminal of SRS main harness 8P connector C503 There should be 0 1 0 Open in the B...

Page 2370: ...SRS main harness replace the SRS main harness Open in the BLU wire of the SRS floor harness replace the SRS floor harness 30 Disconnect dashboard wire harness A 21P connector C505 from the right side...

Page 2371: ...ashboard wire harness A replace dashboard wire harness A Go to step 34 34 Disconnect SRS floor harness 28P connector A from the SRS main harness connector C851 35 Check resistance between the No 27 te...

Page 2372: ...o to step 9 9 Turn the ignition switch OFF 10 Check the No 11 10A fuse in the driver s under dash fuse relay box Go to step 11 Replace the fuse then turn the ignition switch ON II If the fuse blows ag...

Page 2373: ...Check resistance between the No 8 terminal of the OPDS unit harness 8P connector D and body ground There should be 0 1 0 Go to step 20 Open in the BLK wire of the right side wire harness passenger s...

Page 2374: ...y ground There should be an open circuit or at least 1 M Go to step 24 Go to step 31 24 Check resistance between the No 27 terminal of SRS unit connector B 28P and the No 7 terminal of the OPDS unit h...

Page 2375: ...th seat heater or OPDS unit harness replace the faulty harness Go to step 27 27 Disconnect SRS main harness 8P connector C503 from dashboard wire harness A 28 Check resistance between the No 27 termin...

Page 2376: ...SRS main harness Open in the BLU wire of the SRS floor harness replace the SRS floor harness 31 Disconnect dashboard wire harness A 21P connector C505 from the right side wire harness 32 Check resista...

Page 2377: ...ashboard wire harness A replace dashboard wire harness A Go to step 35 35 Disconnect SRS floor harness 28P connector A from the SRS main harness connector C851 36 Check resistance between the No 27 te...

Page 2378: ...heck that the SRS indicator comes on for about 6 seconds and then goes off Replace the front passenger s weight sensor unit see page 23 391 Intermittent failure system is OK at this time Go to Trouble...

Page 2379: ...e the seat assembly see page 20 81 and front passenger s weight sensors then reinstall them Calibrate the front passenger s weight sensor unit see page 23 42 Retry the troubleshooting 1 Erase the DTC...

Page 2380: ...3 Check the connection at the OPDS sensor harness connector and the OPDS unit connector Go to step 4 Reconnect the OPDS sensor harness connector and clear the DTC 4 Replace the OPDS sensor seat back...

Page 2381: ...ke sure nothing is on the front passenger s seat 4 Check the No 9 10A fuse in the driver s under dash fuse relay box Go to step 5 Repair the short to ground in the No 9 10A fuse circuit 5 from the OPD...

Page 2382: ...e assembly see page 22 100 10 Turn the ignition switch ON II 11 Check for voltage between the No 4 terminal of gauge assembly connector A 14P and body ground There should be battery voltage Go to step...

Page 2383: ...P with seat heater or right side wire harness 4P without seat heater and OPDS unit harness 4P connectors if the connection is OK replace the OPDS unit harness Poor contact at gauge assembly connector...

Page 2384: ...tage between the No 3 terminal of the OPDS unit harness 8P connector D and body ground There should be battery voltage Faulty OPDS unit replace the OPDS unit see page 23 387 Go to step 7 7 Turn the ig...

Page 2385: ...n goes off Go to step 3 Intermittent failure system is OK at this time Go to Troubleshooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable a...

Page 2386: ...1 0 Open in dashboard wire harness A replace dashboard wire harness A Go to step 9 9 Disconnect SRS floor harness 28P connector A from the SRS main harness connector C851 10 Check resistance between t...

Page 2387: ...terminal of SRS unit connector A 28P and body ground Turn the ignition switch ON II and measure voltage There should be 1 6 V or less Open in the SRS indicator circuit or poor contact at gauge assembl...

Page 2388: ...ooting Intermittent Failures see page 23 39 3 Turn the ignition switch OFF Disconnect the battery negative cable and wait for 3 minutes 4 Disconnect SRS unit connector A 28P from the SRS unit 5 Remove...

Page 2389: ...ashboard wire harness A replace dashboard wire harness A Go to step 9 9 Disconnect SRS floor harness 28P connector A from the SRS main harness connector C851 10 Check resistance between the No 19 term...

Page 2390: ...t connector A 28P and body ground Turn the ignition switch ON II and measure voltage There should be 1 6 V or less Short to ground in SRS indicator circuit or poor contact at gauge assembly connector...

Page 2391: ...is OK if DTC 92 1x is still present go to step 6 6 Check the No 9 10A fuse in the driver s under dash fuse relay box Go to step 7 Replace the fuse then turn the ignition switch ON II If the fuse blow...

Page 2392: ...terminal of SRS unit connector A 28P to body ground with a jumper wire 15 Turn the ignition switch ON II 16 Check the passenger s airbag cutoff indicator Faulty SRS unit replace the SRS unit see page...

Page 2393: ...place the passenger s airbag cutoff indicator Go to step 21 21 Disconnect SRS floor subharness 28P connector A from the SRS floor harness connector C582 22 Check resistance between the No 4 terminal o...

Page 2394: ...bharness replace the SRS floor subharness Go to step 25 25 Disconnect dashboard wire harness A 21P connector C501 from the left side wire harness 26 Check resistance between the No 4 terminal of the d...

Page 2395: ...h OFF Disconnect the battery negative cable and wait for 3 minutes 5 Disconnect SRS unit connector A 28P from the SRS unit 6 Check resistance between the No 20 terminal of SRS unit connector A 28P and...

Page 2396: ...arness replace the left side wire harness Go to step 11 11 Disconnect SRS floor subharness 28P connector A from the SRS floor harness connector C852 12 Check resistance between the No 20 terminal of S...

Page 2397: ...le 3 Disconnect SRS unit connector A 28P from the SRS unit 4 Reconnect the battery negative cable 5 Connect a voltmeter between the No 17 terminal of SRS unit connector A 28P and body ground Turn the...

Page 2398: ...relay box connector N 2P and the driver s under dash fuse relay box check the connection If the connection is OK replace the driver s under dash fuse relay box Go to step 9 9 Disconnect SRS main harne...

Page 2399: ...r dash fuse relay box 6 Disconnect the battery negative cable 7 Disconnect SRS unit connector A 28P from the SRS unit 8 Reconnect the battery negative cable 9 Turn the ignition switch ON II and wait f...

Page 2400: ...the ignition switch OFF 16 Disconnect driver s under dash fuse relay box connector N 2P 17 Check resistance between the No 2 terminal of driver s under dash fuse relay box connector N 2P and the No 18...

Page 2401: ...k resistance between the No 2 terminal of driver s under dash fuse relay box connector N 2P and the No 18 terminal of SRS main harness 28P connector C851 There should be 0 1 0 Open in the SRS floor ha...

Page 2402: ...p 3 3 Replace the No 9 7 5A fuse and check to see if the SRS indicator comes on The system is OK Go to step 4 4 Check for an open in the wire harness between fuse No 9 7 5A and the gauge assembly and...

Page 2403: ...al of the SRS main harness 3P connector and body ground 15 Turn the ignition switch ON II and measure the voltage Short to power in the BLU wire of the SRS main harness repair the harness Go to step 1...

Page 2404: ...en the No 6 terminal of the SRS main harness 18P connector and body ground 21 Turn the ignition switch ON II and measure the voltage There should be 0 5 V or less Faulty SRS unit replace the SRS unit...

Page 2405: ...Erase the DTC memory by SCS menu method see page 23 38 Go to step 37 Go to step 2 2 Check the No 2 10A fuse in the driver s under dash fuse relay box Go to step 17 Go to step 3 3 Replace the No 2 10A...

Page 2406: ...r A from the driver s under dash fuse relay box 15 Turn the ignition switch ON II and wait for 30 seconds Then turn the ignition switch OFF 16 Check the No 2 10A fuse in the driver s under dash fuse r...

Page 2407: ...ition switch OFF 23 Disconnect the SRS main harness 2P connector A from the under dash fuse relay box 24 Check resistance between the No 3 terminal of SRS main harness 18P connector and the No 2 termi...

Page 2408: ...2 10A fuse in the driver s under dash fuse relay box Go to step 35 Go to step 32 32 Replace the No 2 10A fuse in the driver s under dash fuse relay box 33 Disconnect the gauge assembly connector C 16P...

Page 2409: ...SRS main harness 18P connector There should be 1 or less Faulty SRS indicator circuit in the gauge assembly or poor contact at the gauge assembly connector C 16P Check the connection If the connectio...

Page 2410: ...tion at the SRS main harness 18P connector and the SRS unit If the connection is OK replace the SRS unit see page 23 382 Open in the SCS line between the No 9 terminal of the SRS main harness 18P conn...

Page 2411: ...n the driver s under dash fuse relay box The system is OK at this time Go to step 5 5 Replace the No 1 15A fuse in the driver s under dash fuse relay box 6 Disconnect the SRS main harness 2P connector...

Page 2412: ...switch OFF 13 Check the No 1 15A fuse in the driver s under dash fuse relay box Short to ground in the SRS unit replace the SRS unit see page 23 382 Short to ground in the SRS main harness replace th...

Page 2413: ...nnection If the connection is OK replace the SRS unit Go to step 19 19 Turn the ignition switch OFF 20 Disconnect the SRS main harness 2P connector A from the driver s under dash fuse relay box 21 Che...

Page 2414: ...d body ground There should be 0 1 0 Go to step 4 Open in the BLK wire of the dashboard wire harness or faulty body ground terminal G503 If the body ground terminal is OK replace the dashboard wire har...

Page 2415: ...nector C 16P and body ground Turn the ignition switch ON II and measure voltage There should be 0 5 V or less Faulty SRS unit replace the SRS unit see page 23 382 Go to step 12 8 Turn the ignition swi...

Page 2416: ...e the gauge assembly Open in the under dash fuse relay box No 9 10A fuse line or open in the YEL wire of the dashboard wire harness If the under dash fuse relay box is OK replace the faulty harness 11...

Page 2417: ...uge assembly connector C 16P and body ground Turn the ignition switch ON II and measure the voltage There should be 0 5 V or less Short to power in the SRS floor harness replace the SRS floor harness...

Page 2418: ...er s SCS mode 1 Erase the DTC memory see page 23 38 Go to step 42 Go to step 2 2 Check the No 2 10A fuse in the under dash fuse relay box Go to step 19 Go to step 3 3 Replace the No 2 10A fuse in the...

Page 2419: ...in the SRS unit replace the SRS unit see page 23 382 Go to step 15 15 Replace the No 2 10A fuse in the under dash fuse relay box 16 Disconnect the driver s under dash fuse relay connector N from the...

Page 2420: ...ry negative cable and wait for 3 minutes 20 Disconnect the driver s airbag 4P connector A 21 Disconnect the front passenger s airbag 4P connector A 22 Disconnect both seat belt tensioner 2P connectors...

Page 2421: ...connector N from the under dash fuse relay box 28 Check resistance between the No 3 terminal of SRS unit connector A 18P and the No 2 terminal of the dashboard wire harness 2P connector There should b...

Page 2422: ...erminal of the SRS unit connector C 8P 36 Check the No 2 10A fuse in the under dash fuse relay box Go to step 40 Go to step 37 37 Replace the No 2 10A fuse in the under dash fuse relay box 38 Remove t...

Page 2423: ...e No 5 terminal of SRS unit connector C 8P There should be 1 or less Faulty SRS indicator circuit in the gauge assembly or poor contact at gauge assembly connector C 16P check the connection If the co...

Page 2424: ...16P or open between the No 4 terminal of the Data Link Connector DLC 16P and body ground Repair the open wire s 45 Disconnect the SRS main harness 28P connector A from the SRS floor harness 28P conne...

Page 2425: ...8 Check resistance between the No 9 terminal of gauge assembly connector C 16P and the No 25 terminal of the SRS main harness 28P connector There should be 1 or less Open in the SRS floor harness repl...

Page 2426: ...ssembly connector B 22P and body ground There should be 0 1 0 Go to step 4 Open in the BLK wire of the dashboard wire harness or faulty body ground terminal G503 If the body ground terminal is OK repl...

Page 2427: ...body ground Turn the ignition switch ON II and measure voltage There should be 0 5 V or less Faulty SRS unit replace the SRS unit see page 23 384 Go to step 12 8 Turn the ignition switch OFF Check the...

Page 2428: ...ce the gauge assembly Open in the under dash fuse relay box No 9 10A fuse line or open in the YEL wire of the dashboard wire harness If the under dash fuse relay box is OK replace the faulty harness 1...

Page 2429: ...auge assembly connector C 16P and body ground Turn the ignition switch ON II and measure the voltage There should be 0 5 V or less Short to power in the SRS floor harness replace the SRS floor harness...

Page 2430: ...0 Disconnect gauge assembly connector C 16P from the gauge assembly 4 Check resistance between the No 9 terminal of gauge assembly connector C 16P and the No 19 terminal of SRS unit connector A 28P Th...

Page 2431: ...replace the SRS floor harness Go to step 7 7 Disconnect the dashboard wire harness 8P 8 gauge assembly connector C 16P and the No 6 0 1 0 Open in the SRS main harness replace the SRS main harness Open...

Page 2432: ...airbag system is OK If the indicator does not function properly use the HDS to read the DTC s If this doesn t retrieve any codes use the Tester s SCS menu method If the SCS method doesn t work you may...

Page 2433: ...g 2P connector C 3 Remove the covers A B from the steering wheel remove the two Torx bolts C using a Torx T30 bit then remove the driver s airbag D 4 Disconnect the horn connector from the steering wh...

Page 2434: ...cable 4 After installing the airbag confirm proper system operation Turn the ignition switch ON II the SRS indicator should come on for about 6 seconds and then go off Make sure the horn button works...

Page 2435: ...h a screwdriver to lift the front passenger s airbag B out of the dashboard NOTE The airbag lid has pawls on its side which attach it to the dashboard 1 Disconnect the battery negative cable and wait...

Page 2436: ...ox 3 Reconnect the battery negative cable 4 After installing the airbag confirm proper system operation Turn the ignition switch ON II the SRS indicator should come on for about 6 seconds and then go...

Page 2437: ...the specified torque Make sure that the seat back cover is installed properly Improper installation may prevent proper deployment Be sure to install the harness wires so they are not pinched or interf...

Page 2438: ...ioners appear intact not deployed treat them with extreme caution Follow this procedure If an SRS equipped vehicle is to be entirely scrapped its airbags side airbags and seat belt tensioners should b...

Page 2439: ......

Page 2440: ...r service it should be deployed as follows 1 Confirm that the special tool is functioning properly by following the check procedure on this page or on the tool label 2 Position the airbag face up outd...

Page 2441: ...s are aligned straight ahead 2 Disconnect the battery negative cable and wait at least 3 minutes 3 Remove the driver s airbag see page 23 368 4 Remove the steering wheel see page 17 22 5 Remove the da...

Page 2442: ...Make sure the front wheels are aligned straight ahead 2 Disconnect the battery negative cable and wait at least 3 minutes 3 Remove the driver s airbag see page 23 368 4 Disconnect the connectors A fro...

Page 2443: ...6 Remove the dashboard lower cover A 7 Remove the column cover screws A then remove the column covers B C 8 Disconnect the SRS main harness 4P connectors A from the cable reel 4P connectors B 9 Relea...

Page 2444: ...SRS main harness 2P connector D 5 Install the steering column covers 6 If necessary center the cable reel New replacement cable reels come centered Do this by first rotating the cable reel clockwise...

Page 2445: ...e on for about 6 seconds and then go off After the SRS indicator has turned off turn the steering wheel fully left and right to confirm the SRS indicator does not come on 13 Check the horn radio remot...

Page 2446: ...a new steering wheel bolt A 8 Reconnect the cruise control set resume switch B radio remote switch C and the horn switch D 9 Install the driver s airbag see page 23 369 10 Reconnect the battery negati...

Page 2447: ...three Torx bolts A from the SRS unit then pull out the SRS unit from the bracket 1 Disconnect the battery negative cable and wait at least 3 minutes before beginning work 2 Disconnect the driver s an...

Page 2448: ...the ignition switch ON II the SRS indicator should come on for about 6 seconds and then go off 1 Install the new SRS unit A with Torx bolts B then connect the connectors C to the SRS unit push it int...

Page 2449: ...nit from the right side 1 Install the new SRS unit A with Torx bolts B then connect the connectors C to the SRS unit push it into position until it clicks NOTE When tightening the Torx bolts to the sp...

Page 2450: ...he center pillar lower trim panel see page 20 58 4 Disconnect the side wire harness 2P connector A from the side impact sensor B 5 Remove the Torx bolt C using a Torx T30 bit then remove the side impa...

Page 2451: ...page 20 60 4 Remove the center pillar lower trim panel see page 20 58 5 Disconnect the side wire harness 2P connector A from the side impact sensor B 6 Remove the Torx bolts C using a Torx T30 bit th...

Page 2452: ...w OPDS unit on the seat back frame Tighten the two screws A and connect the OPDS unit harness 8P connector and sensor connectors to the OPDS unit 2 Install the seat back cover see page 20 102 3 Instal...

Page 2453: ...e beginning work 2 Remove the front bumper see page 20 128 3 Disconnect the side wire harness 2P connector A and remove the two Torx bolts B using a Torx T30 bit then remove the front impact sensor C...

Page 2454: ...the evaporative emissions canister hose 3 Disconnect the engine compartment wire harness 2P connector A and remove the two Torx bolts B using a Torx T30 bit then remove the front sensor C NOTE Be sur...

Page 2455: ...ing nuts A then remove the front passenger s weight sensors B from the seat riser NOTE Be sure to install the harness wires so they are not pinched or interfering with other parts Do not turn the igni...

Page 2456: ...t sensors unit B from the seat riser NOTE Be sure to install the harness wires so they are not pinched or interfering with other parts 1 Place the new front passenger s weight sensors unit on the seat...

Page 2457: ...P connector without power seat from the driver s seat position sensor A 4 Remove the Torx bolt B using a Torx T30 bit then remove the driver s seat position sensor NOTE Be sure to install the harness...

Page 2458: ...el see page 20 68 2 Disconnect the 4P connector A from the passenger airbag cutoff indicator B 3 Push out the passenger s airbag cutoff indicator from behind the center panel C 4 Check for continuity...

Page 2459: ......

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Honda 2004 Odyssey, Service Manual

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Summary of Contents for 2004 Odyssey

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