Mazda 6 2002 Workshop Manual Download Page 1242

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SPECIAL TOOLS

ST–3

End Of Sie

FUEL AND EMISSION CONTROL SYSTEMS

A6E941001001W04

End Of Sie

CLUTCH

A6E941001024W01

End Of Sie

MANUAL TRANSAXLE

A6E941001024W02

End Of Sie

49 B019 901B

Oil Pressure
Gauge

49 N013 101A

Body

49 N013 102A

Adapter Hose

49 L018 001

O2 sensor
wrench

49 T042 001

Union wrench

WDS

49 0259 770B

Flare Nut
Wrench

49 SE01 310A

Clutch Disc
Centering Tool

49 E011 1A0

Ring Gear
Brake Set

49 G030 795

Oil Seal Installer

49 E017 5A0

Engine Support
Set

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Summary of Contents for 6 2002

Page 1: ...notice All rights reserved No part of this book may be reproduced or used in any form or by any means electronic or mechanical including photocopying and recording and the use of any kind of informati...

Page 2: ...00001 JM7 GG34F 100001 JM7 GG42F 100001 JM7 GG44F 100001 RELATED MATERIALS Mazda6 Training Manual European L H D GCC Specs 3359 1 02C Engine Workshop Manual L8 LF L3 1731 1 02C Manual Transaxle Worksh...

Page 3: ...effective methods of performing service and repair Some require tools specifically designed for a specific purpose Persons using procedures and tools which are not recommended by Mazda Motor Corporat...

Page 4: ...E CLAMPS GI 16 TORQUE FORMULAS GI 16 VISE GI 16 DYNAMOMETER GI 17 SST GI 17 INSTALLATION OF RADIO SYSTEM GI 17 INSTALLATION OF RADIO SYSTEM GI 17 ELECTRICAL SYSTEM GI 18 ELECTRICAL PARTS GI 18 CONNECT...

Page 5: ...Simple operations which can be performed easily just by looking at the vehicle i e removal installation of parts jacking vehicle lifting cleaning of parts and visual inspection have been omitted End...

Page 6: ...le parts tightening torques and symbols for oil grease and sealant are shown in the overview illustration In addition symbols indicating parts requiring the use of special service tools or equivalent...

Page 7: ...if the caution is ignored Note A Note provides added information that will help you to complete a particular procedure Specification The values indicate the allowable range when performing inspection...

Page 8: ...DTC is shown specifying the cause of a malfunction continue the diagnostic inspection according to the items indicated by the on board diagnostic function Diagnostic index The diagnostic index lists...

Page 9: ...rm each step in the order shown The reference column lists the location of the detailed procedure for each basic inspection Although inspections and adjustments are performed according to the referenc...

Page 10: ...HOW TO USE THIS MANUAL GI 7 GI Using the DTC troubleshooting flow DTC troubleshooting flow shows diagnostic procedures inspection methods and proper action to take for each DTC XME2010004...

Page 11: ...THIS MANUAL Using the diagnosis index The symptoms of the malfunctions are listed in the diagnostic index for symptom troubleshooting The exact malfunction symptoms can be selected by following the i...

Page 12: ...tive in quickly narrowing down the relation between symptom and cause of the malfunction It also specifies the area of the common cause when multiple malfunction symptoms occur The appropriate diagnos...

Page 13: ...10 HOW TO USE THIS MANUAL Using the symptom troubleshooting Symptom troubleshooting shows diagnostic procedures inspection methods and proper action to take for each trouble symptom End Of Sie XME2010...

Page 14: ...ions 210 260 kPa 2 1 2 7 kgf cm2 30 38 psi 270 310 kPa 2 7 3 2 kgf cm2 39 45 psi The actual converted values for 2 7 kgf cm2 are 264 kPa and 38 4 psi In the first specification 2 7 is used as an upper...

Page 15: ...equired End Of Sie OIL LEAKAGE INSPECTION A6E201400004W04 Use either of the following procedures to identify the type of oil that is leaking Using UV Light Black Light 1 Remove on the engine or transa...

Page 16: ...disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS unit to deplete its stored power Disconnecting the battery cable will delete the memo...

Page 17: ...the parts to be replaced from those that will be reused End Of Sie CLEANING OF PARTS A6E201400004W10 All parts to be reused should be carefully and thoroughly cleaned in the appropriate method Warnin...

Page 18: ...d be installed before sealant hardens to prevent leakage Oil should be applied to the moving components of parts Specified oil or grease should be applied at the prescribed locations such as oil seals...

Page 19: ...ated due to the extra length that the SST or equivalent adds to the torque wrench Recalculate the torque using the following formulas Choose the formula that applies to you A The length of the SST pas...

Page 20: ...sition run the vehicle at 10km h and check that the ABS warning light goes off In this case a DTC will be stored in the memory To delete this data from the memory follow the procedure for deleting DTC...

Page 21: ...p the hook of the clip using a flathead screwdriver End Of Sie CONNECTORS A6E201700006W02 Data link connector Insert the probe into the terminal when connecting a jumper wire to the data link connecto...

Page 22: ...n When a tester is used to inspect for continuity or measuring voltage insert the tester probe from the wiring harness side Inspect the terminals of waterproof connectors from the connector side since...

Page 23: ...locking tab pressed down pull the terminal out from the connector Sensors Switches and Relays Handle sensors switches and relays carefully Do not drop them or strike them against other objects Wiring...

Page 24: ...ort and the wiring should be inspected Be sure the negative battery terminal is disconnected before replacing a main fuse When replacing a pullout fuse use the fuse puller Direction of View for Connec...

Page 25: ...rminal side the direction of view is from the terminal side End Of Sie ELECTRICAL TROUBLESHOOTING TOOLS A6E201700006W03 Jumper wire A jumper wire is used to create a temporary circuit Connect the jump...

Page 26: ...circuits Caution Do not connect the ohmmeter to any circuit where voltage is applied This will damage the ohmmeter End Of Sie PRECAUTIONS BEFORE WELDING A6E201700006W04 Vehicles have various electric...

Page 27: ...vehicle after it has been lifted Front At the jacking plate of the engine support member Rear At the center of torsion beam axle Vehicle Lift Positions Front and rear Warning Unstably lifting a vehicl...

Page 28: ...GI 25 GI JACKING POSITIONS VEHICLE LIFT 2 SUPPORTS SAFETY STANDS RIGID RACK POSITIONS Jacking positions vehicle lift 2 supports and safety stand rigid rack positions view End Of Sie A6E2021W001...

Page 29: ...age to the transaxle Caution Do not tow with sling type equipment This could damage your vehicle Use wheel lift or flatbed equipment Caution Do not use the hook loops under the front and rear for towi...

Page 30: ...be completely removed Do not use excessive force as it may damage the cap or scratch the painted bumper surface 3 Securely install the towing eyelet using the lug wrench 4 Hook the towing rope to the...

Page 31: ...IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER VIN A6E202600010W01 End Of Sie ENGINE IDENTIFICATION NUMBER A6E202600010W02 End Of Sie IDENTIFICATION NUMBER LOCATIONS A6E2026W004 A6E202...

Page 32: ...rvice Code s DI Distributor Ignition Spark Ignition DLI Distributorless Ignition Direct Ignition EI Electronic Ignition Electronic Spark Ignition 2 ECT Engine Coolant Temperature Water Thermo EM Engin...

Page 33: ...tion System Injection with air pump SAPV Secondary Air Pulse Valve Reed Valve SFI Sequential Multipoint Fuel Injection Sequential Fuel Injection Shift Solenoid A 12 Shift Solenoid Valve Shift A Soleno...

Page 34: ...eft front LH Left hand L H D Left hand drive LO Low LR Left rear M Motor MAX Maximum MTX Manual transaxle O D Overdrive OCV Oil control valve OFF Switch off ON Switch on P S Power steering P W CM Powe...

Page 35: ...lights Cigarette lighter and clock Ignition switch and steering lock Transaxle range switch ATX only Warning buzzers Seat belts warning system Ignition key reminder alarm Seat controls sliding and rec...

Page 36: ...cle is operated in very dusty or sandy areas clean and if necessary replace the air cleaner element more often than the recommended intervals 4 If the brakes are used extensively for example continuou...

Page 37: ...drive belts if installed 2 If the vehicle is operated under any of the following conditions change the engine oil and oil filter every 10 000 km 6 000 miles or shorter a Driving in dusty conditions b...

Page 38: ...Months 12 24 36 48 60 72 84 96 108 120 132 144 1000 km 15 30 45 60 75 90 105 120 135 150 165 180 1000 miles 9 18 27 36 45 54 63 72 81 90 99 108 To ensure efficient operation of the engine and all syst...

Page 39: ...d I I I I I I I I E G R system if installed I I I I I I I I ELECTRICAL SYSTEM Battery electrolyte level specific gravity I I I I I I I I All electrical system 4 I I I I I I I I CHASSIS BODY Brake clut...

Page 40: ...k of electrical systems such as lights wiper and washer systems including wiper blades and power windows 6 If the vehicle is operated under any of the following conditions change the rear differential...

Page 41: ...or 4WD 7 Front and rear suspension and ball joints I I I I Drive shaft dust boots I I I I Bolts and nuts on chassis and body T T T T T T T T Exhaust system and heat shields Inspect every 80 000 km 50...

Page 42: ...rottle positioner system Check the diaphragm and system operation vacuum fitting hoses and connection Dash pot for carburetor Check system operation E G R system Check system operation see W M vacuum...

Page 43: ...Check oil level and inspect for leakage Replace transfer oil Upper arm shafts for B Series Lubricate the upper arm shafts for looseness or damage Front rear wheel bearing grease Remove wheel bearing...

Page 44: ...IMING CHAIN REMOVAL INSTALLATION B 10 CYLINDER HEAD GASKET B 18 CYLINDER HEAD GASKET REPLACEMENT B 18 FRONT OIL SEAL B 21 FRONT OIL SEAL REPLACEMENT B 21 REAR OIL SEAL B 25 REAR OIL SEAL REPLACEMENT B...

Page 45: ...MBLY 4 Timing Chain See B 10 TIMING CHAIN REMOVAL INSTALLATION 5 Cylinder head gasket See B 18 CYLINDER HEAD GASKET REPLACEMENT 6 Front oil seal See B 21 FRONT OIL SEAL REPLACEMENT 7 Rear oil seal See...

Page 46: ...lace the drive belt SeeB 3 DRIVE BELT REPLACEMENT End Of Sie DRIVE BELT REPLACEMENT A6E221015800W03 1 Remove the splash shield RH 2 Turn the center of the tensioner pulley clockwise to release tension...

Page 47: ...in the figure If the valve clearance exceeds the space the tappet See B 5 VALVE CLEARANCE ADJUSTMENT Note Make sure to note the measured values for choosing the suitable replacement tappets Standard E...

Page 48: ...connector 7 Remove the ventilation hose 8 Remove the cylinder head cover 9 Remove the drive belt See B 3 DRIVE BELT REPLACEMENT 10 Remove the joint shaft from the front drive shaft RH See M 17 DRIVE...

Page 49: ...at the position where the tension is released 17 Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown 18 Remove the exhaust camshaft sprocket 19 Loosen the camshaft cap bolt...

Page 50: ...steps 1 Tighten to 5 0 9 0 N m 51 0 91 7 kgf cm 44 3 79 5 in lbf 2 Tighten to 14 0 17 0 N m 1 5 1 7 kgf m 10 4 12 5 ft lbf 25 Install the exhaust camshaft sprocket Note Do not tighten the bolt for the...

Page 51: ...2 N m 1 9 2 2 kgf m 13 3 16 2 ft lbf 37 Install the new engine front cover lower blind plug Tightening torque 12 N m 1 2 kgf m 8 9 ft lbf 38 Connect the front drive shaft RH and the joint shaft See M...

Page 52: ...auge into the spark plug hole 8 Fully depress the accelerator pedal and crank the engine 9 Note the maximum gauge reading 10 Inspect each cylinder as above If the measured value is less than the limit...

Page 53: ...e tire RH 4 Remove the under cover 5 Loosen the water pump pulley bolt and removal the drive belt See B 3 DRIVE BELT REPLACEMENT 6 Remove the CKP sensor See F 54 CRANKSHAFT POSITION CKP SENSOR REMOVAL...

Page 54: ...acket Removal Note See B 16 No 3 Engine Mount Rubber and No 3 Engine Joint Bracket Installation Note 7 Engine front cover See B 14 Engine Front Cover Installation Note 8 Front oil seal See B 13 Engine...

Page 55: ...shaft pully by using the SSTs Chain Tensioner Removal Note 1 Using a thin screwdriver hold the chain tensioner ratchet lock mechanism away from the ratchet stem 2 Slowly compress the tensioner piston...

Page 56: ...e 1 Hold the oil pump sprocket by using the SST Engine Front Cover Removal Note 1 Remove the oil seal using a screwdriver as shown Oil Pump Sprocket Installation Note 1 Hold the oil pump sprocket by u...

Page 57: ...o tensioner to apply tension to the timing chain Engine Front Cover Installation Note 1 Apply silicone sealant to the engine front cover as shown Caution Install the cylinder head cover within 10 minu...

Page 58: ...tion Note 1 Apply clean engine oil to the oil seal 2 Push the oil seal slightly in by hand 3 Compress the oil seal using the SST and a hammer Bolt No Tightening torque 1 18 8 0 11 5 N m 81 6 117 2 kgf...

Page 59: ...7 0 13 N m 71 4 132 5 kgf cm 62 0 115 0 in lbf 2 Install the No 3 engine mount rubber hand tighten 3 Tighten the No 3 engine joint bracket is attached and bolts nuts in the order shown Crankshaft Pull...

Page 60: ...from the cylinder block lower blind plug 9 Rotate the crankshaft clockwise two turns until the TDC position If not aligned loosen the crankshaft pulley lock bolt and repeat from Step 1 10 Install the...

Page 61: ...STALLATION 2 Remove the ignition coil See G 8 IGNITION COIL REMOVAL INSTALLATION 3 Remove the high tension lead See G 10 1 HIGH TENSION LEAD REMOVAL INSTALLATION 4 Disconnect the generator but do not...

Page 62: ...eir original position When removed keep the caps with the cylinder head they were removed from Do not mix the caps AME2218W002 1 Camshaft See B 19 Camshaft Removal Note See B 21 Camshaft Installation...

Page 63: ...th of each cylinder head bolt Replace any that exceed maximum length Length L 149 0 150 0 mm 5 867 5 905 in Maximum 150 5 mm 5 965 in 2 Tighten the cylinder head bolts in the order shown using the fol...

Page 64: ...he spark plugs See G 10 SPARK PLUG REMOVAL INSTALLATION 3 Remove the Cylinder head cover See B 17 Cylinder Head Cover Installation Note 4 Remove the drive belt See B 3 DRIVE BELT REPLACEMENT 5 Remove...

Page 65: ...all the SST 3 Turn the crankshaft clockwise the crankshaft is in the No 1 cylinder TDC position 4 Hold the crankshaft pulley by using the SSTs Front Oil Seal Removal Note 1 Cut the oil seal lip using...

Page 66: ...l seal lip 2 Push the oil seal slightly in by hand 3 Tap the oil seal in evenly using the SST and a hammer Crankshaft Pulley Lock Bolt Installation Note 1 Install the SST to the camshaft as shown Euro...

Page 67: ...ghten to 96 104 N m 9 8 10 6 kgf m 70 9 76 7 ft lbf 2 Tighten 87 93 6 Remove the M6 x 1 0 bolt 7 Remove the SST from the camshaft 8 Remove the SST from the cylinder block lower blind plug 9 Rotate the...

Page 68: ...Rear Oil Seal Installation Note 1 Apply silicone sealant to the mating faces as shown Dot diameter 4 0 6 0 mm 0 16 0 23 in 2 Apply clean engine oil to the new oil seal lip 3 Install the rear oil seal...

Page 69: ...o that it is out of the way Use wire or rope to secure 7 Remove the joint shaft from the front drive shaft See M 17 DRIVE SHAFT REMOVAL INSTALLATION 8 Remove the air cleaner intake air duct accelerato...

Page 70: ...e B 31 No 1 Engine Mount Bracket Installation Note 3 No 4 Engine mount bracket and No 4 Engine mount rubber See B 28 No 4 Engine Mount Bracket and No 4 Engine Mount Rubber Removal Note See B 30 No 4 E...

Page 71: ...oosen the through bolt B on the chassis side until approximately three pitches are showing Note Do not remove the No 1 engine mount rubber from the vehicle No 4 Engine Mount Bracket and No 4 Engine Mo...

Page 72: ...4 No 4 engine mount bracket and engine mount rubber together in one piece No 3 Engine Joint Bracket Installation Note 1 Tighten the No 3 engine mount bracket stud bolt Tightening torque 7 0 13 N m 71...

Page 73: ...unt Rubber Installation Note 1 Tighten the No 4 engine mount bracket and No 4 engine mount rubber bolt and nut in the order as shown 2 Secure the engine and the transaxle using an engine jack and atta...

Page 74: ...116 6 N m 9 50 11 88 kgf m 68 72 85 92 ft lbf End Of Sie ENGINE DISASSEMBLY ASSEMBLY A6E222401001W02 1 Disconnect the engine and automatic transaxle ATX See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLATI...

Page 75: ...t secured Replace the actuator 8 Install the cylinder head cover See B 17 Cylinder Head Cover Installation Note 9 Install the ventilation hose 10 Install the oil control valve connector 11 Install the...

Page 76: ...ve battery cable 2 Remove the plug hole plate 3 Remove the high tension lead See G 10 1 HIGH TENSION LEAD REMOVAL INSTALLATION 4 Remove the oil control valve OCV connector 5 Remove the ventilation hos...

Page 77: ...valve terminals and verify that the spool valve operates and moves to the maximum valve timing advance position If not as specified replace the oil control valve Note When applying battery positive v...

Page 78: ...D 3 OIL PRESSURE INSPECTION D 3 ENGINE OIL D 4 ENGINE OIL INSPECTION D 4 ENGINE OIL REPLACEMENT D 4 OIL FILTER D 6 OIL FILTER REPLACEMENT D 6 OIL COOLER D 7 OIL COOLER REMOVAL INSTALLATION D 7 OIL PA...

Page 79: ...Of Sie LOCATION INDEX AME3300W001 1 Oil filter See D 6 OIL FILTER REPLACEMENT 2 Oil cooler LF and L3 engine models See D 7 OIL COOLER REMOVAL INSTALLATION 3 Oil pan See D 8 OIL PAN REMOVAL INSTALLATI...

Page 80: ...nd repair or replace as necessary Note The oil pressure can vary with oil viscosity and temperature Oil pressure Oil temperature 100 C 212 F L8 LF 234 521 kPa 2 39 5 31 kgf cm2 33 9 75 5 psi min 3 000...

Page 81: ...ehicle on level ground 2 Remove the oil filler cap 3 Remove the under cover 4 Remove the oil pan drain plug 5 Drain the engine oil into a container 6 Install the oil pan drain plug With washer 1 Insta...

Page 82: ...If the oil leaks specify the faulty part and repair or replace it 10 Inspect the oil level If necessary add oil See D 4 ENGINE OIL INSPECTION 11 Install the under cover End Of Sie A6E0110W001 DIPSTIC...

Page 83: ...the filter 5 Loosen the oil filter cover for another 1 turn 6 Remove the oil filter cover and the oil filter 7 Use a clean rag to wipe off the mounting surface on the oil filter adapter and the oil f...

Page 84: ...l to the gasket of a new oil filter 5 Tighten the oil filter with specified tightening torque Tightening torque 15 20 N m 1 6 2 0 kgf m 11 24 ft lbf 6 Remove the dipstick and verify that the oil level...

Page 85: ...ntainer See D 6 OIL FILTER REPLACEMENT 4 Remove in the order indicated in the table 5 Use a clean rag to wipe off the mounting surface on the oil cooler 6 Install in the reverse order of removal 7 Ins...

Page 86: ...engine oil See D 4 ENGINE OIL REPLACEMENT 4 Remove the engine front cover See B 10 TIMING CHAIN REMOVAL INSTALLATION 5 Remove in the order indicated in the table 6 Install in the reverse order of rem...

Page 87: ...re ruler to unite the oil pan and the cylinder block junction side on the engine front cover side 2 Apply silicone sealant to the oil pressure switch threads as shown 3 Tighten the bolts in the order...

Page 88: ...verse order of removal 6 Inspect the engine oil level See D 4 ENGINE OIL INSPECTION 7 Start the engine and inspect for oil leakage If the oil leaks specify the faulty part and repair or replace it 8 I...

Page 89: ...OIL PUMP D 11 D Oil Pump Sprocket Removal Installation Note 1 Install the SST to the oil pump sprocket to stop the oil pump from turn in End Of Sie AME3322W002...

Page 90: ...E 3 ENGINE COOLANT REPLACEMENT E 4 ENGINE COOLANT LEAKAGE INSPECTION E 4 RADIATOR CAP E 5 RADIATOR CAP INSPECTION E 5 RADIATOR E 6 RADIATOR REMOVAL INSTALLATION E 6 THERMOSTAT E 7 THERMOSTAT REMOVAL...

Page 91: ...adiator cap See E 5 RADIATOR CAP INSPECTION 3 Thermostat See E 7 THERMOSTAT REMOVAL INSTALLATION See E 8 THERMOSTAT INSPECTION 4 Water pump See E 8 WATER PUMP REMOVAL INSTALLATION 5 Cooling fan See E...

Page 92: ...F and L marks If the engine coolant level is below L remove the radiator cap and add coolant See E 3 COOLING SYSTEM SERVICE WARNINGS End Of Sie ENGINE COOLANT PROTECTION INSPECTION A6A361215001W04 1...

Page 93: ...ngine warms up perform the following steps 1 Run the engine at 2 500 rpm for 5 min 2 Run the engine at 3 000 rpm for 5 s then return to idling 3 Repeat Step 2 several times 4 Run the engine at idle fo...

Page 94: ...d radiator are hot Scalding coolant and steam may shoot out and cause serious injury It may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very ca...

Page 95: ...Remove the cooling fan See E 9 COOLING FAN REMOVAL INSTALLATION 4 Remove the oil hose ATX 5 Remove in the order indicated in the table 6 Install in the reverse order of removal 7 Refill the engine coo...

Page 96: ...REPLACEMENT 5 Remove the washer tank 6 Remove the P S oil pump Note Remove the P S oil pump with hoses and pipe still connected 7 Remove in the order indicated in the table 8 Install in the reverse or...

Page 97: ...TEM SERVICE WARNINGS See E 4 ENGINE COOLANT REPLACEMENT 3 Loosen the water pump pulley bolt to remove the drive belt See B 3 DRIVE BELT REPLACEMENT 4 Remove in the order indicated in the table 5 Insta...

Page 98: ...shroud panel See S 119 SHROUD PANEL REMOVAL INSTALLATION 3 Remove the A C pipe stay 4 Remove the ATX pipe stay ATX 5 Remove in the order indicated in the table 6 Install in the reverse order of remov...

Page 99: ...2 1 Remove the cooling fan See E 9 COOLING FAN REMOVAL INSTALLATION 2 Remove in the order indicated in the table 3 Install in the reverse order of removal 4 End Of Sie AME3621W002 1 Cooling fan No 2 2...

Page 100: ...es smoothly at the standard current draw If not as spcifid replace the fan motor End Of Sie TERMINAL No B A COOLING FAN HARNESS CONNECTOR LF COOLING FAN MOTOR No 1 2 L3 COOLING FAN MOTOR No 1 No 2 A B...

Page 101: ...N F 34 PULSATION DAMPER INSPECTION F 34 EXHAUST SYSTEM F 35 EXHAUST SYSTEM INSPECTION F 35 EXHAUST SYSTEM REMOVAL INSTALLATION F 35 EMISSION SYSTEM F 38 CHARCOAL CANISTER INSPECTION F 38 EVAPORATIVE G...

Page 102: ...G F 181 ENGINE SYMPTOM TROUBLESHOOTING F 181 QUICK DIAGNOSTIC CHART F 182 NO 1 MELTING OF MAIN OR OTHER FUSES F 186 NO 2 MIL ILLUMINATES F 186 NO 3 WILL NOT CRANK F 187 NO 4 HARD TO START LONG CRANK E...

Page 103: ...trol solenoid valve L3 See F 13 VARIABLE AIR DUCT VAD CONTROL SOLENOID VALVE INSPECTION L3 7 VIS shutter valve actuator L3 See F 14 VARIABLE INTAKE AIR SYSTEM VIS SHUTTER VALVE ACTUATOR INSPECTION L3...

Page 104: ...F 4 LOCATION INDEX End Of Sie FUEL SYSTEM A6E390001006W01 Engine Room Side A6E3912W015...

Page 105: ...uel pump unit See F 22 FUEL PUMP UNIT REMOVAL INSTALLATION See F 24 FUEL PUMP UNIT DISASSEMBLY ASSEMBLY See F 25 FUEL PUMP UNIT INSPECTION 4 Fuel injector See F 28 FUEL INJECTOR REMOVAL INSTALLATION S...

Page 106: ...LENOID VALVE REMOVAL INSTALLATION See F 39 PURGE SOLENOID VALVE INSPECTION 3 Evaporative gas check valve one way L H D See F 38 EVAPORATIVE GAS CHECK VALVE ONE WAY INSPECTION L H D 4 PCV valve See F 4...

Page 107: ...F 54 CRANKSHAFT POSITION CKP SENSOR REMOVAL INSTALLATION 6 CMP sensor See F 55 CAMSHAFT POSITION CMP SENSOR INSPECTION 7 Knock sensor See F 56 KNOCK SENSOR INSPECTION See F 56 KNOCK SENSOR REMOVAL INS...

Page 108: ...iming is not adjustable Ignition timing verification requires WDS or equivalent 1 Turn off the electrical loads 2 Warm up the engine as follows 1 Start the engine 2 Maintain the engine speed at approx...

Page 109: ...e accelerator pedal 4 Wait until the cooling fans stop 3 Verify that the idle speed and ignition timing are within the specification See F 8 IDLE SPEED INSPECTION See F 8 IGNITION TIMING INSPECTION 4...

Page 110: ...hazardous It can easily ignite causing serious injury and damage Always keep sparks and flames away from fuel Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or...

Page 111: ...Air cleaner cover 2 Air cleaner element 3 Air cleaner case See F 12 Air Cleaner Case Installation Note 4 Resonance chamber See F 12 Resonance Chamber Removal Note 5 VAD control solenoid valve L3 6 VAD...

Page 112: ...ounts are set in the air cleaner bracket 3 locations 2 Install the projections on the frame side 2 locations 3 Verify that the projections on the frame side are installed securely 4 Install the projec...

Page 113: ...l C harness side Short circuit If there is continuity the circuit is shorted Repair or replace the harness VAD control solenoid valve terminal B harness side and body GND VAD control solenoid valve te...

Page 114: ...ess side and GND IAC valve terminal B harness side and power supply IAC valve terminal B harness side and GND End Of Sie VARIABLE INTAKE AIR SYSTEM VIS SHUTTER VALVE ACTUATOR INSPECTION L3 A6E39101300...

Page 115: ...INSPECTION A6E391013000W07 1 Remove the air hose See F 10 INTAKE AIR SYSTEM REMOVAL INSTALLATION 2 Disconnect the vacuum hose from the VTCS shutter valve actuator 3 Connect a vacuum pump to the VTCS s...

Page 116: ...ply End Of Sie ACCELERATOR PEDAL REMOVAL INSTALLATION A6E391041600W01 1 Remove in the order indicated in the table 2 Install in the reverse order of removal Accelerator Cable Installation Note 1 Carry...

Page 117: ...PROCEDURE A6E391201006W02 Warning Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage When installing the fuel hose observe Fuel Leakage Inspectio...

Page 118: ...release connector Always clean the quick release connector joint area before disconnecting connecting using a cloth or soft brush and make sure that it is free of foreign material 1 Level the vehicle...

Page 119: ...at it is free of foreign material Note This inspection is for two rollover valves integrated in the fuel tank 1 Disconnect the plastic fuel hose and the fuel pump unit connector See F 22 FUEL PUMP UNI...

Page 120: ...age are dangerous Fuel can ignite and cause serious injuries or death Fuel can also irritate skin and eyes To prevent this always complete the BEFORE REPAIR PROCEDURE See F 17 BEFORE REPAIR PROCEDURE...

Page 121: ...he fuel line pressure If not as specified inspect the following Zero or low FP circuit FP Fuel line clogged Fuel leakage inside pressure regulator High Pressure regulator for high pressure cause Fuel...

Page 122: ...ER REPAIR PROCEDURE End Of Sie FUEL PUMP UNIT REMOVAL INSTALLATION A6E391213350W01 Warning Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fue...

Page 123: ...ke care not to lose it Reinstall it to the quick release connector before reconnecting the fuel line The locking coupler has two internal locking tabs which retain the fuel pipe Be sure that the tab o...

Page 124: ...or so that the tabs of the retainer are correctly fitted into the quick release connector Push the quick release connector straight into the retainer until a click is heard 4 Lightly pull and push the...

Page 125: ...erials penetrate the part Otherwise it may cause a fuel pump unit operation malfunction Protect any removed parts using rubber matting to prevent damage Furthermore if a part has been dropped do not r...

Page 126: ...r replaced separately Type A With nylon tube replaced as a single unit 2WD NYLON TUBE FUEL PUMP FUEL FILTER HIGH PRESSURE C6E114ZL4026 Specification With nylon tube Without nylon tube Single Separatel...

Page 127: ...CUP RESERVE CUP FUEL GAUGE SENDER UNIT FUEL GAUGE SENDER UNIT DISASSEMBLY ASSEMBLY FUEL PUMP FUEL PUMP SEAL RUBBER SPACER C6E114ZL4016 A A A A R OIL OIL R OIL OIL OIL OIL R B B B B SET PLATE HOLDING...

Page 128: ...ERVE CUP FUEL GAUGE SENDER UNIT DISASSEMBLY ASSEMBLY HOLDING COVER DISASSEMBLY ASSEMBLY FUEL PUMP SEAL RUBBER SPACER C6E114ZL4017 A A R OIL OIL R OIL OIL OIL OIL R B B HOLDING COVER FUEL FILTER HIGH P...

Page 129: ...ve the fuel gauge sender unit 2 Disconnect the fuel pump connector 3 Remove the arm part of the set plate FUEL PUMP UNIT FUEL GAUGE SENDER UNIT C6E114ZL4002 FUEL PUMP CONNECTOR C6E114ZL4014 SET PLATE...

Page 130: ...damage 4 Cut the center part of the nylon tube located between the fuel filter high pressure and set plate Type A B C Note Perform Step 5 4WD Go to Step 6 2WD 5 Disconnect the quick release connector...

Page 131: ...e Note Perform Step 9 4WD Go to Step 10 2WD Note After removing the fuel filter high pressure from the reserve cup remove the transfer jet pump completely 4WD 9 Remove the transfer jet pump from the r...

Page 132: ...Perform Step 15 type B Go to Step 23 type A Go to Step 19 type C Type B Caution Cut the nylon tube in the center If it is cut at the both ends it may cause pipe damage 15 Cut apart the nylon tube in t...

Page 133: ...mp discharge pipe or pull the fuel filter low pressure or it may damage the discharge pipe or dislocate tear the fuel filter low pressure 20 Remove the fuel pump from the fuel filter high pressure 21...

Page 134: ...discharge pipe Verify that the lower case is not split chipped or bent Caution Hold the fuel pump in the upright position and insert it from the bottom side being careful not to apply load to the fuel...

Page 135: ...el hose is buckled and fuel flow distortion occurs it may cause jet pump performance deterioration 8 Install a new O ring to the pressure regulator Note Perform Step 9 4WD Go to Step 11 2WD 9 Install...

Page 136: ...me time 4WD 16 Install the pressure regulator holding cover and verify that the snap fit tab is properly engaged Note Perform Step 17 4WD Go to Step 18 2WD 17 Connect the quick release connector to th...

Page 137: ...erve cup outward 2 Rotate the set plate 90 counter clockwise viewing the set plate from above Caution Be careful not to break the set plate arm by applying excessive pressure If it is broken it may ca...

Page 138: ...nnector side wiring harness is routed underside 3 Route the wiring harness under projection 2 4 Connect the connector 22 Perform the following procedure to connect the fuel pump connector routing the...

Page 139: ...ction The fuel gauge sender unit connector wiring harness is not pulled The fuel pump connector wiring harness is not pinched into the pressure regulator holding cover 24 Inspect the following and ver...

Page 140: ...TION 3 Disconnect the fuel pump unit connector 4 Inspect for continuity between fuel pump unit connector terminals B and D If there is no continuity replace the fuel pump body If as specified carry ou...

Page 141: ...1 Complete the BEFORE REPAIR PROCEDURE See F 17 BEFORE REPAIR PROCEDURE 2 Disconnect the negative battery cable 3 Remove the air cleaner Caution The quick release connector may be damaged if the tab i...

Page 142: ...l pump hold pressure More than 200 kPa 2 0 kgf cm2 29 psi 14 Disconnect the jumper wire 15 Disconnect the SST Note A checker tab is integrated with the quick release connector for new plastic fuel hos...

Page 143: ...ER REPAIR PROCEDURE See F 17 AFTER REPAIR PROCEDURE Plastic Fuel Hose Removal Note Caution The quick release connector may be damaged if the tab is bent excessively Do not expand the tab over the stop...

Page 144: ...l cause the injector to not engage correctly Always use a new clip when reattaching the injector otherwise it may cause the injector to rotate 1 Insert a screwdriver between the injector cup and the c...

Page 145: ...ith the clip locked onto the injector cup notch Plastic Fuel Hose Installation Note Note A checker tab is integrated with quick release connector for new plastic fuel hoses The checker tab will be rel...

Page 146: ...43 PCM REMOVAL INSTALLATION 2 Inspect the following wiring harness for open or short continuity check Open circuit If there is no continuity the circuit is open Repair or replace the harness No 1 cyl...

Page 147: ...tor with the fuel hose connected See F 28 FUEL INJECTOR REMOVAL INSTALLATION 4 Fasten the fuel injectors firmly to the fuel distributor with wire 5 Connect the negative battery cable Caution Connectin...

Page 148: ...AIR PROCEDURE 2 Disconnect the negative battery cable 3 Remove the fuel injectors See F 28 FUEL INJECTOR REMOVAL INSTALLATION 4 Connect the fuel injector to the fuel injector tester 5 Measure the inje...

Page 149: ...stall the pressure regulator See F 28 FUEL INJECTOR REMOVAL INSTALLATION End Of Sie PULSATION DAMPER INSPECTION A6E391220180W02 1 Complete the BEFORE REPAIR PROCEDURE See F 17 BEFORE REPAIR PROCEDURE...

Page 150: ...eplace as necessary End Of Sie EXHAUST SYSTEM REMOVAL INSTALLATION A6E391440000W02 Warning When the engine and exhaust system are hot they can badly burn Turn off the engine and wait until they are co...

Page 151: ...F 36 EXHAUST SYSTEM A6E3914W002...

Page 152: ...manifold installation nuts in the order shown End Of Sie 1 Main silencer 2 Middle pipe 3 TWC 4 Exhaust manifold insulator upper 5 Bracket 6 Exhaust manifold See F 37 Exhaust Manifold Installation Note...

Page 153: ...ply negative pressure to port A and verify that there is air flow If there is no airflow replace the evaporative gas check valve one way End Of Sie PURGE SOLENOID VALVE REMOVAL INSTALLATION A6E3916187...

Page 154: ...ss side and PCM terminal 4U Purge solenoid valve terminal B harness side and main relay terminal C harness side Short circuit If there is continuity the circuit is shorted Repair or replace the harnes...

Page 155: ...inuity the circuit is open Repair or replace the harness EGR valve terminal E harness side and PCM terminal 4E EGR valve terminal A harness side and PCM terminal 4H EGR valve terminal B harness side a...

Page 156: ...min at 65 96 km h 40 60 mph to allow the front catalytic converter to reach operating temperature 4 Stop the vehicle and leave it in a safe place 5 Let the engine idle 6 Record PIDs for 1 min 7 Selec...

Page 157: ...tream HO2S inversions 5 inversions downstream HO2S inversions 6 0 good WU TWC Downstream HO2S graph line example 2 Downstream HO2S graph line example 3 Equation RATIO 30 inversions upstream HO2S inver...

Page 158: ...tery cable 2 For R H D perform the following procedures 1 Remove the front side trim left side 2 Partially peel back the flower covering 3 Remove in the order indicated in the table 4 Install in the r...

Page 159: ...ead of the set nut bolt so that a screwdriver can be inserted 2 Loose the set nut bolt using an impact screwdriver or pliers Set Nut bolt Installation Note 1 Install a new set nut bolt and tighten it...

Page 160: ...voltmeter to measure the PCM terminal voltage The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION INSPECTION are as follows ACCS ALTF EVAPCP FAN1 FAN2 FAN3 FP HTR11 HTR12 IAC IAS...

Page 161: ...edal depressed ON Clutch pedal released OFF Inspect clutch switch See F 59 CLUTCH SWITCH INSPECTION 1R CPP PNP Shift lever position ON OFF Neutral position ON Others OFF Inspect neutral switch See F 5...

Page 162: ...ON 0 Idle Approx 60 ECT 90 C 194 F and E L not operating Inspect following PIDs IAT RPM MAP ECT MAF TP INGEAR TR PSP ACSW Inspect IAC valve See F 13 IDLE AIR CONTROL IAC VALVE INSPECTION 4G 4J IASV Va...

Page 163: ...gnition switch ON 0 1 0 V Idle After warm up 0 1 0 V Acceleration After warm up 0 5 1 0 V Deceleration After warm up 0 0 5 V Inspect HO2S front See F 56 HEATED OXYGEN SENSOR HO2S INSPECTION 1AB O2S12...

Page 164: ...T1 Short term fuel trim Idle after warm up approx 30 25 Perform applicable DTC troubleshooting See F 67 DTC TABLE SPARKADV Ignition timing BTC Ignition switch ON BTDC 0 Idle BTDC approx 10 Inspect fol...

Page 165: ...See G 9 IGNITION COIL INSPECTION Inspect related harness 1C GND GND Under any condition Below 1 0 Inspect related harness 1D GND GND Under any condition Below 1 0 Inspect related harness 1E 1F 1G Atmo...

Page 166: ...R 1 Clutch operation Clutch switch Clutch pedal depressed Below 1 0 Inspect clutch switch See F 59 CLUTCH SWITCH INSPECTION Inspect related harness Clutch pedal released B 1S 1T 1U 1V 1W Neutral posit...

Page 167: ...coil control Generator terminal D Inspect using the wave profile See F 48 10 Inspection Using An Oscilloscope Reference Inspect following PIDs IAT ECT RPM VPWR ALTT V Inspect generator Inspect related...

Page 168: ...POSITION CMP SENSOR INSPECTION Inspect related harness 2N 2O 2P Knocking Knock sensor Ignition switch ON Use digital type voltmeter because measurement voltage will be detected less than true voltage...

Page 169: ...profile See F 48 10 Inspection Using An Oscilloscope Reference Inspect VSS Inspect related harness 3D 2 ATF temperature TFT sensor Ignition switch ON TFT 20 C 68 F Approx 3 3 Inspect TFT sensor Inspe...

Page 170: ...valve Inspect using the wave profile See F 48 10 Inspection Using An Oscilloscope Reference Inspect pressure control solenoid valve Inspect related harness 3Z 3AA 4A HO2S Front heater control HO2S Fr...

Page 171: ...harness 4K EGR valve 3 coil control EGR valve terminal B Ignition switch ON B Inspect EGR valve See F 40 EGR VALVE INSPECTION Inspect related harness Idle B 4L Cooling fan control Cooling fan relay I...

Page 172: ...ference Inspect fuel injector No 2 See F 31 FUEL INJECTOR INSPECTION Inspect related harness 4X GND GND Under any condition Below 1 0 Inspect related harness 4Y 2 Shift solenoid C control Shift soleno...

Page 173: ...al PCM terminals 1AA 2AC Oscilloscope setting 2 V DIV Y 2 ms DIV X DC range Vehicle condition Idle after warm up engine speed approx 650 rpm MTX or 700 rpm ATX no load P S off A C off HO2S front signa...

Page 174: ...s DIV X DC range Vehicle condition Idle after warm up engine speed approx 650 rpm MTX or 700 rpm ATX no load P S off A C off PCM terminals 2G 2H Oscilloscope setting 2 V DIV Y 4 ms DIV X DC range Vehi...

Page 175: ...dle after warm up engine speed approx 650 rpm MTX or 700 rpm ATX no load P S off A C off L3 engine PCM terminals 2M 2H Oscilloscope setting 1 V DIV Y 10 ms DIV X DC range Vehicle condition Idle after...

Page 176: ...ondition Idle after warm up engine speed approx 650 rpm MTX or 700 rpm ATX no load P S off A C off PCM terminals 3Y 1C Oscilloscope setting 5 V DIV Y 1 ms DIV X DC range Vehicle condition Idle after w...

Page 177: ...d approx 650 rpm MTX or 700 rpm ATX no load P S off A C off OCV control signal PCM terminals 4J 1C Oscilloscope setting 2 V DIV Y 0 8 ms DIV X DC range Vehicle condition Idle after warm up engine spee...

Page 178: ...V Y 5 ms DIV X DC range Vehicle condition Idle after warm up engine speed approx 650 rpm MTX or 700 rpm ATX no load P S off A C off Shift solenoid A control PCM terminals 4AB 1C Oscilloscope setting 5...

Page 179: ...n the MAF IAT sensor terminals D and E using an ohmmeter If not as specified replace the MAF IAT sensor If the MAF IAT sensor is okay but the IAT PID are out of specification perform the Circuit Open...

Page 180: ...ty the circuit is shorted Repair or replace the harness MAF sensor terminal A harness side and body GND MAF sensor terminal C harness side and power supply MAF sensor terminal C harness side and body...

Page 181: ...OFF 3 Select MAP PID on the SSTs WDS or equivalent 4 Verify that the MAP PID pressure and barometric pressure are practically equal If not as verified perform the Circuit Open Short Inspection If ther...

Page 182: ...CT sensor in water with a thermometer and heat the water gradually 4 Measure the resistance between the ECT sensor terminals A and B using an ohmmeter If not as specified replace the ECT sensor If the...

Page 183: ...B harness side and PCM terminal 2G harness side Short circuit If there is continuity the circuit is shorted Repair or replace the harness CKP sensor terminal A harness side and power supply CKP senso...

Page 184: ...is no foreign material on the CMP sensor when replacing Note Perform the following inspection only when directed Resistance Inspection 1 Disconnect the CMP sensor connector 2 Measure the resistance b...

Page 185: ...rness side and PCM terminal 2S harness side Knock sensor terminal B harness side and PCM terminal 2P harness side Short circuit If there is continuity the circuit is shorted Repair or replace the harn...

Page 186: ...is open Repair or replace the harness Front HO2S terminal A harness side and PCM terminal 1AB harness side HO2S terminal B harness side and PCM terminal 2H harness side Rear HO2S terminal A harness s...

Page 187: ...orm the following inspection only when directed Continuity Inspection 1 Inspect the following if the power steering is inoperative See N 4 POWER STEERING FLUID INSPECTION Power steering fluid level Po...

Page 188: ...llowing harness for open or short Continuity check Open circuit Clutch switch terminal B harness side and PCM terminal 1R Clutch switch terminal D and body GND Short circuit Clutch switch terminal B h...

Page 189: ...ext step 5 Apply vacuum of 25 0 kPa 187 mmHg 7 38 inHg to the barometric pressure sensor and verify that the BARO variation from that of Step 4 is approx 25 0 kPa 187 mmHg 7 38 inHg If not as verified...

Page 190: ...iagnose the malfunction according to following flowchart If a DTC exists diagnose the applicable DTC inspection See F 67 DTC TABLE If no DTC exists and the MIL does not illuminate or flash diagnose th...

Page 191: ...ws OBD system operating status If any monitor function is incomplete WDS or equivalent will identify which monitor function has not been completed Misfires Fuel System and Comprehensive Components CCM...

Page 192: ...FRAME DATA by WDS or equivalent On Board System Readiness Tests Access Procedure 1 Perform the necessary vehicle preparation and visual inspection 2 Connect WDS or equivalent to the vehicle DLC 2 16 p...

Page 193: ...S menu PCM Adaptive Memory Procedure Drive Mode Note The PCM adaptive memory condition can be confirmed with RFCFLAG PID If RFCFLAG PID is ON PCM Adaptive Memory Procedure Drive Mode is not necessary...

Page 194: ...pleted initial value is displayed End Of Sie Zone Shift Position Vehicle Speed km h mph Time Sec O Neutral 0 0 T1 Above 455 A 2nd 40 50 25 32 T2 Above 30 B 3rd 65 75 41 47 C 2nd 60 75 38 46 T3 Above 2...

Page 195: ...order then go to next step No Go to next step 2 VERIFY RELATED REPAIR INFORMATION Check for related Service information availability Is any related repair information available Yes Perform repair or d...

Page 196: ...TP circuit low input ON 1 CCM See F 100 DTC P0122 P0123 TP circuit high input ON 1 CCM See F 102 DTC P0123 P0125 Excessive time to enter closed loop fuel control ON 2 CCM See F 104 DTC P0125 P0131 Fro...

Page 197: ...706 Transaxle range TR switch circuit range performance See K 53 DTC TABLE P0707 Transaxle range TR switch circuit low input See K 53 DTC TABLE P0708 Transaxle range TR switch circuit high input See K...

Page 198: ...162 DTC P1410 P1562 PCM BB voltage low ON 1 CCM See F 164 DTC P1562 P2006 Variable tumble control system shutter valve stuck closed ON 2 CCM See F 166 DTC P2006 P2009 Variable tumble control solenoid...

Page 199: ...CM terminal 4M Short to power between OCV terminal A and PCM terminal 4M Open circuit between OCV terminal A and PCM terminal 4M Poor connection of OCV connector or PCM connector PCM malfunction STEP...

Page 200: ...NECTOR FOR POOR CONNECTION Turn ignition key to OFF Disconnect PCM connector Inspect for poor connection at terminal 4M damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair...

Page 201: ...gine Increase engine speed Stop engine Remove the OCV Inspect the position of spool valve in OCV Is spool valve located at valve retard position Yes Go to next step No Replace OCV then go to Step 5 3...

Page 202: ...G procedure See F 227 INTERMITTENT CONCERN TROUBLESHOOTING 2 VERIFY RELATED PENDING CODE OR STORED DTCS Is DTC P0010 present Yes Go to DTC P0010 troubleshooting procedure See F 70 DTC P0010 No Go to n...

Page 203: ...nal at PCM terminal 4A If PCM turns front HO2S heater off but front HO2S heater circuit has low voltage PCM determines that front HO2S heater circuit has malfunction Note Front HO2S heater is controll...

Page 204: ...then go to Step 8 No Go to next step 3 INSPECT FRONT HO2S HEATER Inspect front HO2S heater See F 56 HEATED OXYGEN SENSOR HO2S INSPECTION Is front HO2S heater okay Yes Go to next step No Replace front...

Page 205: ...9 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See F 66 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troubleshooting...

Page 206: ...go to Step 6 No Go to next step 3 INSPECT FRONT HO2S HEATER Inspect front HO2S heater See F 56 HEATED OXYGEN SENSOR HO2S INSPECTION Is front HO2S heater okay Yes Go to next step No Replace the front...

Page 207: ...HO2S heater control signal at PCM terminal 4D If PCM turns rear HO2S heater off but rear HO2S heater circuit has low voltage PCM determines that rear HO2S heater circuit has malfunction Diagnostic su...

Page 208: ...CONNECTION OF PCM CONNECTOR Turn ignition key to OFF Disconnect PCM connector Inspect for poor connection damaged pulled out pins corrosion etc Are there any malfunctions Yes Repair terminal then go t...

Page 209: ...ATA is available DTC is stored in PCM memory POSSIBLE CAUSE Short to power circuit between rear HO2S terminal D and PCM terminal 4D Rear HO2S or PCM terminal is shorted Rear HO2S heater malfunction PC...

Page 210: ...m throttle position sensor or engine speed If mass intake air flow amount is below 5 0 g sec 0 66 lb min for 5 s and throttle opening angle is above 50 with engine running the PCM determines that dete...

Page 211: ...nals corrosion etc Is there any malfunction Yes Repair or replace suspected terminal or MAF IAT sensor then go to Step 7 No Go to next step 6 INSPECT POOR CONNECTION OF PCM CONNECTOR Disconnect PCM co...

Page 212: ...completed STEP INSPECTION ACTION DTC P0102 MAF circuit low input DETECTION CONDITION PCM monitors input voltage from MAF sensor when engine running If input voltage at PCM terminal 1P is below 0 21 V...

Page 213: ...damaged pulled out terminals corrosion etc Is there any malfunction Yes Repair terminal then go to Step 7 No Go to next step 5 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR OPEN CIRCUIT Remove PCM with PCM co...

Page 214: ...IBLE CAUSE MAF sensor malfunction Connector or terminal malfunction Short to power in wiring between MAF IAT sensor terminal C and PCM terminal 1P Open circuit in MAF IAT sensor ground circuit STEP IN...

Page 215: ...OER self test See F 66 KOEO KOER SELF TEST Is same DTC present Yes Replace PCM then go to next step See F 43 PCM REMOVAL INSTALLATION No Go to next step 7 VERIFY AFTER REPAIR PROCEDURE Perform After R...

Page 216: ...07 go to CONSTANT VOLTAGE troubleshooting procedure Turn ignition key to ON Engine OFF Measure voltage between MAP sensor terminal C harness side and body ground Is voltage within 4 5 5 5 V Yes Check...

Page 217: ...resent Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troubleshooting completed STEP INSPECTION ACTION DTC P0108 MAP sensor circuit high input DETECTION CONDITION PCM monitors input vo...

Page 218: ...SOR CONNECTOR Disconnect the MAP sensor connector Inspect for poor connection damaged pulled out pins corrosion etc Is there any malfunction Yes Repair or replace suspected terminal then go to Step 8...

Page 219: ...ignition key on the PCM determines that there is a IAT sensor performance problem Diagnostic support note This is a continuous monitor CCM MIL illuminates if PCM detects the above malfunction conditio...

Page 220: ...Y AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troubleshooting completed STEP INSPECTION ACTION DTC P0112 IAT circuit low input DETECT...

Page 221: ...nsor terminals D and E harness side Is there continuity Yes Repair or replace harness for short then go to Step 6 No Go to next step 6 VERIFY TROUBLESHOOTING OF DTC P0112 COMPLETED Make sure to reconn...

Page 222: ...ulled out pins corrosion etc Are there any malfunctions Yes Repair or replace terminal then go to Step 8 No Go to next step 3 CLASSIFY IAT SENSOR MALFUNCTION OR HARNESS MALFUNCTION Connect WDS or equi...

Page 223: ...DS or equivalent Perform KOEO KOER self test See F 66 KOEO KOER SELF TEST Is same DTC present Yes Replace PCM then go to next step See F 43 PCM REMOVAL INSTALLATION No Go to next step 9 VERIFY AFTER R...

Page 224: ...to next step 3 CLASSIFY ECT SENSOR MALFUNCTION OR HARNESS MALFUNCTION Connect WDS or equivalent to DLC 2 Access ECT PID Verify ECT value when disconnecting ECT sensor connector Does ECT value change...

Page 225: ...TION ACTION DTC P0118 ECT circuit high input DETECTION CONDITION PCM monitors ECT sensor signal at PCM terminal 1M If PCM detects ECT sensor voltage above 4 6 V PCM determines that ECT sensor circuit...

Page 226: ...place harness for short to power then go to Step 8 No Go to next step 5 INSPECT POOR CONNECTION OF PCM CONNECTOR Disconnect PCM connector Inspect for poor connection damaged pulled out pins corrosion...

Page 227: ...voltage supply circuit Voltage drops in ground circuit MAF sensor malfunction PCM malfunction STEP INSPECTION ACTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Has FREEZE FRAME DATA been recorded Ye...

Page 228: ...terminal 2K TP sensor connector terminal B harness side and PCM terminal 2A Is voltage approx 0 V Yes Go to next step No Inspect for rust or corrosion on PCM terminals 2A and 2K harness side Repair o...

Page 229: ...NSTALLATION No Go to next step 17 VERIFY AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troubleshooting completed STEP INSPECTION ACTION...

Page 230: ...xt step No Go to step 4 3 INSPECT TP SENSOR Perform TP sensor inspection See F 51 THROTTLE POSITION TP SENSOR INSPECTION Is TP sensor okay Yes Inspect for poor TP sensor connector terminal C connectio...

Page 231: ...t step See F 43 PCM REMOVAL INSTALLATION No Go to next step 8 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See F 66 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable...

Page 232: ...minals corrosion etc Is there any malfunction Yes Repair or replace suspected terminal then go to Step 9 No Go to next step 4 INSPECT TP SENSOR Perform TP sensor inspection See F 51 THROTTLE POSITION...

Page 233: ...to reach the temperature necessary to start closed loop fuel control Diagnostic support note This is a continuous monitor CCM MIL illuminates if PCM detects the above malfunction condition in two con...

Page 234: ...ow Front HO2S stuck high DETECTION CONDITION PCM monitors input voltage from front HO2S when the following monitoring conditions are met If input voltage from sensor remains below or above 0 45 V for...

Page 235: ...decreased Yes Engine is driven under rich condition Go to next step No Engine is driven under lean condition Go to step 9 7 INSPECT FUEL LINE PRESSURE EXCESSIVE FUEL LINE PRESSURE Turn ignition key t...

Page 236: ...or replace wiring harness then go to Step 19 15 INSPECT IGNITION COIL RESISTANCE Check ignition coil resistance See G 9 IGNITION COIL INSPECTION Is coil resistance okay Yes Go to next step No Replace...

Page 237: ...4 at 2 000 rpm Engine speed 1 410 4 000 rpm MTX Engine speed 1 190 4 000 rpm ATX Vehicle speed is above 3 76 km h Engine coolant temperature is above 10 C 14 F Front HO2S signal inversion cycle is ab...

Page 238: ...FREEZE FRAME DATA recorded at Step 1 Is it below FFD value Yes Engine is driven under rich condition Go to next step No Engine is driven under lean condition Go to step 10 9 INSPECT FUEL LINE PRESSURE...

Page 239: ...o next step 14 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See F 66 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Trou...

Page 240: ...opriate DTC troubleshooting procedures No Go to next step 3 IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA Is DTC P0134 on FREEZE FRAME DATA Yes Go to next step No Go to troubleshooting procedures for DTC...

Page 241: ...RESSION Inspect engine compression See B 9 COMPRESSION INSPECTION Is it okay Yes Go to next step No Implement engine overhaul for repairs then go to next step 9 VERIFY TROUBLESHOOTING OF DTC P0134 COM...

Page 242: ...iate DTC troubleshooting procedures See F 67 DTC TABLE No Go to next step 4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA Is DTC P0138 on FREEZE FRAME DATA Yes Go to next step No Go to troubleshooting pr...

Page 243: ...ION PCM monitors input voltage from rear HO2S when the following conditions are met If input voltage from sensor never exceed 0 55 V for 30 4 s PCM determines that sensor circuit is not activated MONI...

Page 244: ...Yes Go to appropriate DTC troubleshooting procedures See F 67 DTC TABLE No Go to next step 3 IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA Is DTC P0140 on FREEZE FRAME DATA Yes Go to next step No Go to t...

Page 245: ...9 No Go to next step 8 INSPECT ENGINE COMPRESSION Inspect engine compression See B 9 COMPRESSION INSPECTION Is it okay Yes Go to next step No Implement engine overhaul for repairs then go to next step...

Page 246: ...NAL STATUS IGNITION KEY TO ON IDLE Access ECT MAF TP and VSS PIDs using WDS or equivalent See F 45 PCM INSPECTION Is there any signal that is far out of specification when ignition key is ON and engin...

Page 247: ...ter high pressure side replace fuel pump unit If foreign materials or stain is found inside fuel filter low pressure side clean of fuel tank and filter If all items above are okay replace fuel pump un...

Page 248: ...e F 66 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troubleshooting completed STEP INSPECTION ACTION DTC P0172 Fuel trim system too ri...

Page 249: ...TX or NEUTRAL MTX Is PID reading okay Above 0 55 V when accelerator pedal is suddenly depress rich condition Below 0 55 V just after release of accelerator pedal lean condition Yes Go to next step No...

Page 250: ...contamination Excess air suction in intake air system between MAF sensor and intake manifold Fuel pump malfunction Fuel pressure regulator malfunction Fuel line clogged Fuel filter clogged Fuel leaka...

Page 251: ...to next step No Replace faulty high tension lead then go to Step 22 10 INSPECT POWER SUPPLY TERMINAL AT IGNITION COIL CONNECTOR Disconnect ignition coil connector Turn ignition key to ON Engine OFF Me...

Page 252: ...ng control system Inspect variable valve timing control system operation Does variable valve timing control system Yes Go to next step No Repair or replace malfunctioning part according to variable va...

Page 253: ...Cylinder No 1 misfire detection Cylinder No 2 misfire detection Cylinder No 3 misfire detection Cylinder No 4 misfire detection DETECTION CONDITION PCM monitors CKP sensor input signal interval time...

Page 254: ...s there any signal which causes drastic changes Yes Inspect suspected circuit and or part according to inspection results Then go to Step 12 See F 45 PCM INSPECTION No Go to next step 6 INSPECT SPARK...

Page 255: ...IFY TROUBLESHOOTING OF MISFIRE DTC COMPLETED Make sure to reconnect all disconnected connectors Start engine Clear DTC from PCM memory using WDS or equivalent Run PCM adaptive memory procedure drive m...

Page 256: ...e F 56 KNOCK SENSOR INSPECTION Is knock sensor okay Yes Go to next step No Replace knock sensor then go to next step 4 INSPECT KNOCK SENSOR CIRCUITS FOR OPEN CIRCUIT Disconnect knock sensor connector...

Page 257: ...o next step 9 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See F 66 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troub...

Page 258: ...then go to step 6 No Go to next step 3 INSPECT KNOCK SENSOR Perform knock sensor inspection See F 56 KNOCK SENSOR INSPECTION Is knock sensor okay Yes Go to next step No Replace knock sensor then go t...

Page 259: ...while MAF is 2 0 g s 0 26 lb min or above PCM determines that CKP sensor circuit has malfunction Diagnostic support note This is a continuous monitor CCM MIL illuminates if PCM detects the above malf...

Page 260: ...age reading Yes Repair or replace suspected harness then go to Step 11 No Go to next step 6 INSPECT CKP CIRCUIT FOR SHORT TO GROUND Inspect continuity between following terminal and body ground CKP se...

Page 261: ...s input signal from CKP sensor PCM determines that CMP circuit has malfunction Diagnostic support note This is a continuous monitor CCM MIL illuminates if PCM detects the above malfunction condition d...

Page 262: ...on If vehicle is not repaired go to next step No Go to next step 3 VERIFY CMP SENSOR VOLTAGE Disconnect CMP sensor connector Connect voltmeter between CMP sensor connector terminals A and B sensor sid...

Page 263: ...form CMP sensor inspection See F 55 CAMSHAFT POSITION CMP SENSOR INSPECTION Is CMP sensor okay Yes Go to Step 15 No Replace CMP sensor and go to step 15 11 VERIFY CKP SENSOR INSTALLATION Verify CKP se...

Page 264: ...Is there any DTC present Yes Go to applicable DTC troubleshooting See F 67 DTC TABLE No Troubleshooting completed STEP INSPECTION ACTION DTC P0403 EGR valve stepper motor circuit malfunction DETECTIO...

Page 265: ...CM terminal 4E Open circuit in wiring between EGR valve terminal A and PCM terminal 4H Open circuit in wiring between EGR valve terminal B and PCM terminal 4K Open circuit in wiring between EGR valve...

Page 266: ...go to Step 9 No Go to next step 7 INSPECT POOR CONNECTION OF PCM Turn ignition key to OFF Disconnect PCM connector Inspect for poor connection damaged pulled out terminals corrosion etc Is there any...

Page 267: ...of front HO2S Looseness of rear HO2S Front HO2S malfunction STEP INSPECTION ACTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Has FREEZE FRAME DATA been recorded Yes Go to next step No Record FREEZE...

Page 268: ...e circuit malfunction DETECTION CONDITION PCM monitors input voltages from purge solenoid valve If voltage at PCM terminal 4U remains low or high PCM determines that purge solenoid valve circuit has m...

Page 269: ...o next step No Replace purge solenoid valve then go to Step 9 6 INSPECT PURGE SOLENOID VALVE POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT Turn ignition key to ON Engine OFF Measure voltage between purge sole...

Page 270: ...al A and PCM terminal 4L Short to ground in wiring between cooling fan relay No 2 terminal A and PCM terminal 4L Short to power circuit between cooling fan relay No 2 terminal A and PCM terminal 4L PC...

Page 271: ...Yes Repair or replace harness for open then go to Step 9 No Go to next step 7 INSPECT PCM CONNECTOR FOR POOR CONNECTION Turn ignition key to OFF Disconnect PCM connector Inspect for poor connection da...

Page 272: ...POSSIBLE CAUSE VSS malfunction ABS TCS DCS malfunction Connector or terminal malfunction Open circuit between PCM terminal 2I and VSS terminal A Open circuit between PCM terminal 2L and VSS terminal...

Page 273: ...VSS terminal A VSS terminal B Is any voltage reading Yes Repair or replace suspected harness then go to Step 11 No Go to next step 7 INSPECT VSS CIRCUIT FOR SHORT TO GROUND Inspect continuity between...

Page 274: ...ge clogged A C relay control circuit malfunction Generator control circuit malfunction Low engine compression Over capacity of blow by gas PCM malfunction STEP INSPECTION ACTION 1 VERIFY RELATED SERVI...

Page 275: ...control system RPM lower than expected DETECTION CONDITION Actual idle speed is lower than expected by 100 rpm for 14 s when brake pedal is depressed brake switch is on and steering wheel is held stra...

Page 276: ...e air cleaner element with engine running Is engine speed increased Yes Replace air cleaner element then go to Step 11 No Go to next step 8 INSPECT THROTTLE BODY PASSAGE Is throttle body clogged Yes C...

Page 277: ...RELATED SERVICE INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service...

Page 278: ...s malfunction Detected threshold value depends on battery voltage and IAC control signal duty value Diagnostic support note This is a continuous monitor CCM MIL illuminates if PCM detects the above ma...

Page 279: ...NTROL CIRCUIT FOR SHORT TO GROUND Turn ignition key to OFF Inspect continuity between following terminals and body ground IAC valve terminal A IAC valve terminal B Is there any continuity Yes Repair o...

Page 280: ...BLE CAUSE PSP switch malfunction Connector or terminal malfunction Short to ground in wiring between PSP switch terminal and PCM terminal 1Z Open circuit in wiring between PSP switch terminal and PCM...

Page 281: ...minal then go to Step 8 No Go to next step 7 INSPECT SIGNAL CIRCUIT MALFUNCTION FOR OPEN CIRCUIT Inspect continuity between PSP terminal A harness side and PCM terminal 1Z Is there any continuity Yes...

Page 282: ...hen go to next step See F 43 PCM REMOVAL INSTALLATION No Go to next step 3 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See F 66 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go...

Page 283: ...PROCEDURE See F 66 DTC CONFIRMATION PROCEDURE Is same DTC present Yes Go to next step No Intermittent concern exists Go to INTERMITTENT CONCERN TROUBLESHOOTING procedure See F 227 INTERMITTENT CONCER...

Page 284: ...Make sure to reconnect all disconnected connectors Turn ignition key to ON Engine OFF Clear DTC from PCM memory using WDS or equivalent Perform KOEO KOER self test See F 66 KOEO KOER SELF TEST Is sam...

Page 285: ...hen go to Step 6 4 INSPECT PCM CONNECTOR FOR POOR CONNECTION Turn ignition key to OFF Disconnect PCM connector Inspect for poor connection at terminal 4R damaged pulled out pins corrosion etc Is there...

Page 286: ...witch malfunction Poor connection of brake switch connector or PCM connector Short to power between brake switch terminal D and PCM connector terminal 1K Open harness between brake switch terminal D a...

Page 287: ...on etc Is there malfunction Yes Repair or replace terminal then go to Step 14 No Go to next step 9 INSPECT BRAKE SWITCH SIGNAL CIRCUIT FOR OPEN CIRCUIT Inspect continuity between brake switch terminal...

Page 288: ...anges in input voltage from clutch switch If PCM does not detect PCM terminal 1R voltage changes while running vehicle with vehicle speed below 30 km h 19mph 8 times alternately PCM determines that cl...

Page 289: ...okay Yes Go to Step 14 No Replace clutch switch then go to Step 14 7 INSPECT CLUTCH SWITCH GROUND CIRCUIT FOR OPEN CIRCUIT Inspect continuity between clutch switch terminal D and ground Is there any...

Page 290: ...TC P0850 Neutral switch circuit malfunction DETECTION CONDITION PCM monitors changes in input voltage from neutral switch If PCM does not detect PCM terminal 1W voltage changes while running vehicle w...

Page 291: ...CPP PNP PID when gear is neutral position Is CPP PNP PID always OFF Yes Go to Next step No Go to Step 10 4 INSPECT NEUTRAL SWITCH CONNECTOR FOR POOR CONNECTION Turn ignition switch to OFF Disconnect n...

Page 292: ...nected Does CPP PNP PID change from ON to OFF Yes Go to next step No Go to Step 13 12 INSPECT NEUTRAL SWITCH Perform neutral switch inspection See F 59 NEUTRAL SWITCH INSPECTION Is neutral switch okay...

Page 293: ...go to Step 5 3 INSPECT POOR CONNECTION OF VAD SOLENOID VALVE CONNECTOR Disconnect VAD solenoid valve connector Inspect for poor connection damaged pulled out terminals corrosion etc Are there any mal...

Page 294: ...PLETED Make sure to reconnect all disconnected connectors Clear DTC from PCM memory using WDS or equivalent Perform KOEO KOER self test See F 66 KOEO KOER SELF TEST Is same DTC present Yes Replace PCM...

Page 295: ...uity Yes Repair or replace harness for short to ground and install new fuse then go to Step 6 No Go to step 6 4 INSPECT POOR CONNECTION OF PCM CONNECTOR Disconnect PCM connector Inspect for poor conne...

Page 296: ...malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM PENDING CODE is available if PCM detects the above malfunc...

Page 297: ...CONTROL SOLENOID VALVE Carry out Variable tumble control solenoid valve airflow inspection See F 15 VARIABLE TUMBLE CONTROL SOLENOID VALVE INSPECTION Is variable tumble control solenoid valve okay Yes...

Page 298: ...control solenoid valve terminal B and PCM terminal 4T Open circuit in wiring between main relay and variable tumble control solenoid valve terminal A Open circuit in wiring between variable tumble con...

Page 299: ...s side and body ground Is there continuity Yes Repair or replace harness for short to ground then go to Step 8 No Go to next step 7 INSPECT VARIABLE TUMBLE CONTROL SOLENOID VALVE CONTROL CIRCUIT FOR O...

Page 300: ...and or variable tumble control solenoid valve Short to power circuit in wiring between variable tumble control solenoid valve terminal B and PCM terminal 4T Variable tumble control solenoid valve malf...

Page 301: ...between PCM terminal 4T and body ground Is voltage B Yes Repair or replace harness for short to power circuit then go to next step No Go to next step 6 VERIFY TROUBLESHOOTING OF DTC P2010 COMPLETED Ma...

Page 302: ...minal A and PCM terminal 1G Open circuit in wiring between BARO sensor terminal C and PCM terminal 2K PCM malfunction STEP INSPECTION ACTION 1 PERFORM DTC CONFIRMATION PROCEDURE Perform DTC CONFIRMATI...

Page 303: ...ct for continuity between BARO sensor terminal B harness side and body ground Is there continuity Yes Repair or replace suspected harness then go to Step 8 No Go to next step 7 INSPECT PCM CONNECTOR F...

Page 304: ...wiring between BARO sensor terminal B and PCM terminal 2H Short to power circuit in wiring between BARO sensor terminal A and PCM terminal 1G PCM malfunction STEP INSPECTION ACTION 1 PERFORM DTC CONF...

Page 305: ...ext step 7 VERIFY BARO SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT Inspect for continuity following terminals Between BARO sensor terminal A and PCM terminal 1G Between BARO sensor terminal B and PCM termi...

Page 306: ...ESHOOTING procedure See F 227 INTERMITTENT CONCERN TROUBLESHOOTING 2 INSPECT BATTERY Turn ignition key to OFF Inspect battery Is battery okay Yes Replace battery then go to Step 6 No Go to next step 3...

Page 307: ...more than 20 A from generator and judges generator output voltage to be below 8 5 V during engine running POSSIBLE CAUSE Generator malfunction PCM and or generator are poorly connected Open and or sh...

Page 308: ...erator terminal D harness side and PCM terminal 1AD harness side Is there continuity Yes Go to next step No Repair or replace harness for open circuit then go to Step 9 8 INSPECT GENERATOR OUTPUT VOLT...

Page 309: ...7 No Go to next step 3 CLASSIFY GENERATOR MALFUNCTION OR OTHER MALFUNCTION Turn ignition key to ON Engine OFF Measure voltage between generator terminal D harness side and body ground Is voltage B Yes...

Page 310: ...MPLETED Make sure to reconnect all connectors Clear DTC from PCM memory using WDS or equivalent Perform KOER self test See F 66 KOEO KOER SELF TEST Is same DTC present Yes Replace PCM then go to next...

Page 311: ...uck jerk Acceleration cruise deceleration Vehicle bucks jerks during acceleration cruising or deceleration Hesitation stumble Acceleration Momentary pause at beginning of acceleration or during accele...

Page 312: ...F 182 TROUBLESHOOTING QUICK DIAGNOSTIC CHART A6E398018881W02 A6E3980W001...

Page 313: ...TROUBLESHOOTING F 183 F A6E3980W002...

Page 314: ...F 184 TROUBLESHOOTING A6E3980W003...

Page 315: ...TROUBLESHOOTING F 185 F End Of Sie A6E3980W004...

Page 316: ...ing fan relay L8 DE LF DE except G C C specs Cooling fan motor ENGINE IG Main relay PCM Ignition coil Condenser METER IG Cooling fan relay PCM ENG BAR VSS ATX OCV VIS solenoid valve VAD control soleno...

Page 317: ...Engine is not completely started DTC B1681 is displayed Yes Both conditions appear Go to Step 4 No Either or other condition appears Go to next step 2 Is coil connector securely connected to coil Yes...

Page 318: ...PID indicated P N when selecting P or N position Yes Go to next step No Inspect adjustment of TR switch If TR switch is adjusted properly inspect for open circuit between TR switch and PCM terminal 1...

Page 319: ...s complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual See F 17 BEFORE REPAIR PROCEDURE See F 17 AFTER REPAIR PROCEDURE Caution Disconnecting connecting quick release c...

Page 320: ...itch is turned off See F 20 FUEL LINE PRESSURE INSPECTION Yes Go to next step No Inspect fuel injector If fuel injector is okay replace fuel pump unit 11 Disconnect a vacuum hose from purge solenoid v...

Page 321: ...s Read the following warnings before performing the fuel system services Fuel vapor is hazardous It can easily ignite causing serious injury and damage Always keep sparks and flames away from fuel Fue...

Page 322: ...eaner element No air leakage from intake air system No restriction of intake air system Proper sealing of intake manifold and components attached to intake manifold EGR valve IAC valve Ignition wiring...

Page 323: ...terminal and body GND Open circuit between ignition switch and ignition coil Open circuit between ignition coil and PCM terminal 1A or 1B 19 Inspect spark plug condition Is spark plug wet covered with...

Page 324: ...evaporative emission control system No Go to next step 26 Is air leakage felt or heard at intake air system components while racing engine to higher speed Yes Repair or replace No Go to next step 27...

Page 325: ...ystem PATS and or circuit malfunction if equipped Pressure regulator malfunction Warning The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures Read the foll...

Page 326: ...eplace wiring harness between coil connector terminal D and fuse panel 10 Verify following Vacuum connection External fuel shut off or accessory kill switch alarm etc Fuel quality proper octane contam...

Page 327: ...l 1A or 1B 20 Inspect spark plug conditions Is spark plug wet covered with carbon or grayish white Yes Spark plug is wet or covered with carbon Inspect for fuel leakage from injector Spark plug is gra...

Page 328: ...es more time than normal to return to idle speed POSSIBLE CAUSE ECT sensor malfunction Thermostat is stuck open Throttle body malfunction Air leakage from intake air system STEP INSPECTION RESULTS ACT...

Page 329: ...lowing troubleshooting flow chart contains fuel system diagnosis and repair procedures Read following warnings before performing the fuel system services Fuel vapor is hazardous It can easily ignite c...

Page 330: ...f crankshaft pulley Are CKP sensor and teeth of crankshaft pulley okay Yes Go to next step No Replace malfunctioning parts 7 Measure gap between CKP sensor and teeth of crankshaft pulley Specification...

Page 331: ...xt step 19 Note The following test should be performed for vehicles with variable valve timing control system Go to next step for vehicles witout variable valve timing control system Inspect variable...

Page 332: ...eration POSSIBLE CAUSE Vacuum leakage IAC valve malfunction Air leakage from intake air system Improper air fuel mixture ratio control Evaporative emission control system malfunction TP sensor misadju...

Page 333: ...PP CPP PNP and TR PIDs Monitor each PID while driving vehicle See F 45 PCM INSPECTION Are PIDs okay Yes Intermittent concern exists See INTERMITTENT CONCERN TROUBLESHOOTING No TP PID Inspect TP sensor...

Page 334: ...rk leakage from high tension leads Air cleaner restriction PCV valve malfunction Improper valve timing due to jumping out timing belt Restriction in exhaust system Intermittent open or short in fuel b...

Page 335: ...r such as vibration intermittent open short circuit VPWR PID Inspect for open circuit intermittently MAF PID Inspect for open circuit of MAF sensor and related wire harness intermittently TP PID Inspe...

Page 336: ...ollowing Refrigerant charging amount Condenser fan operation 14 Note The following test should be performed for symptom with cruise control ON If other symptoms exist go to next step Inspect cruise co...

Page 337: ...X malfunction ATX Clutch slippage MTX Warning The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures Read the following warnings before performing the fuel s...

Page 338: ...Yes Go to next step No Adjust CKP sensor 7 Inspect spark plug condition Is spark plug wet covered with carbon or grayish white Yes Spark plug is wet or covered with carbon Inspect for fuel leakage fr...

Page 339: ...d valve is sticks open mechanically Inspect evaporative emission control system No Go to next step 16 Visually inspect CMP sensor and projections of camshaft pulley Are CMP sensor and projections of c...

Page 340: ...ssibly cause damage to fuel pipe and quick release connector Always clean quick release connector joint area before disconnecting connecting and make sure that it is free of foreign material STEP INSP...

Page 341: ...angerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE describe...

Page 342: ...valve timing control system Go to next step for vehicles without variable valve timing control system Inspect for variable valve timing control system operation See F 239 Variable Valve Timing Contro...

Page 343: ...r death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual See F 17 BEFORE REPAIR PROCEDURE See...

Page 344: ...ce charcoal canister No Inspect fuel tank vent system Then go to next step 9 Is there restriction in exhaust system Yes Inspect exhaust system No Inspect EGR system See F 233 EGR Control System Inspec...

Page 345: ...No DTC is displayed Go to next step 3 Start engine and run it at idle speed Turn A C switch on Does A C compressor engage Yes Go to Step 5 No Inspect for following and repair or replace as necessary...

Page 346: ...CAUSE Thermostat malfunction Condenser fan system malfunction Cooling fan system malfunction STEP INSPECTION RESULTS ACTION 1 Is customer complaint Lack of passenger compartment heat only Yes Inspect...

Page 347: ...ng it may possibly cause damage to fuel pipe and quick release connector Always clean quick release connector joint area before disconnecting connecting and make sure that it is free of foreign materi...

Page 348: ...rdous It can easily ignite causing serious injury and damage Always keep sparks and flames away from fuel Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death...

Page 349: ...mproper drive belt tension Rap or roar sound noise Exhaust system looseness Other noise Camshaft friction gear noise or MLA noise Timing chain noise STEP INSPECTION RESULTS ACTION 1 Is squeal click or...

Page 350: ...there any DTCs displayed Yes DTC is displayed Go to appropriate DTC test No No DTC is displayed Go to next step 2 Disconnect A C compressor connector Start engine and turn A C switch on Is there corr...

Page 351: ...ent or clearance 3 Connect WDS or equivalent to DLC 2 Access ACSW PID Start engine and turn A C switch on Read ACSW PID while disconnecting refrigerant pressure switch connector Note ACSW PID should r...

Page 352: ...OCEDURE Caution Disconnecting connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector Always clean quick release connector joint area...

Page 353: ...with PCM Turn ignition switch to ON position Attempt to access ECT PID Can ECT PID be accessed Yes Go to Step 7 No Go to next step 5 Turn ignition switch off Disconnect TP sensor and PCM connectors Tu...

Page 354: ...ance between battery negative terminal and PCM terminals 4X 2AB and 2AC Is each resistance less than 5 0 ohms Yes Go to next step No Repair open GND circuit 12 Turn ignition switch off Measure resista...

Page 355: ...lete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE described in this manual See F 17 BEFORE REPAIR PROCEDURE See F 17 AFTER REPAIR PROCEDURE Caution Disconnecting connecting quick release connect...

Page 356: ...line pressure correct See F 20 FUEL LINE PRESSURE INSPECTION Yes Go to next step No Zero or low Inspect for clogged fuel line If okay replace fuel pump unit High Replace fuel pump unit 12 Inspect fol...

Page 357: ...wall body panels etc are the major areas to be checked Inspection Method for Switch Connectors or Wires 1 Connect WDS or equivalent to DLC 2 2 Turn ignition key to ON position Engine OFF Note If engin...

Page 358: ...eck for poor connection and or poorly mounted actuator or relay Note Vibrating relays too strongly may result in open relays Water Sprinkling Method Caution Indirectly change the temperature and humid...

Page 359: ...able free play Fuel injector insulator Engine compression See B 9 COMPRESSION INSPECTION Idle Air Control System Inspection Engine coolant temperature compensation inspection 1 Connect WDS or equivale...

Page 360: ...displayed If DTC P0661 or P0662 is shown carry out DTC inspection See F 67 DTC TABLE 4 Turn ignition switch to ON 5 Turn the VIS control solenoid valve from on to off using the IVC PID and verify that...

Page 361: ...s the accelerator pedal and increase the engine speed to 4 000 rpm 2 Release the accelerator pedal brake pedal is not depressed and verify that the fuel injector duration time is 0 msec and 2 5 msec w...

Page 362: ...he following procedure Warning High voltage in the ignition system can cause strong electrical shock which can result in serious injury Avoid direct contact to the vehicle body during the following sp...

Page 363: ...NSPECTION 10 Stop the vehicle and verify that the SEGRP value is returned 0 Purge Control System Inspection 1 Start the engine 2 Disconnect the vacuum hose between the purge solenoid valve and the cha...

Page 364: ...ivalent to DLC 2 2 Verify that ECT PID is below cooling fan operating temperature 3 Verify that A C switch and fan switch are off 4 Turn the ignition switch to ON position 5 Verify that the cooling fa...

Page 365: ...No 2 and PCM terminal 4B Open circuit between cooling fan relay No 2 and cooling fan motor No 2 or fan motor GND Cooling fan relay No 2 is stuck open Cooling fan motor No 2 If both cooling fan No 2 an...

Page 366: ...PCM 1AC related harnesses and connectors 10 Access the COLP PID 11 Verify that the cooling fan is operating high speed an condenser fan is operating low speed while the COLP PID is ON If the cooling f...

Page 367: ...operation sound is not heard inspect cooling fan relay No 2 and open circuit between PCM terminal 4L and cooling fan relay No 2 wiring harness and connectors Inspect the cooling fan is operating high...

Page 368: ...operation sound is not heard inspect cooling fan relay No 3 and open circuit wiring harnesses and connectors between PCM terminal 4B and cooling fan relay No 3 Variable Air Duct VAD Control System Ope...

Page 369: ...DUTY1 PID 5 Set the oil control valve OCV duty valve to 100 and verify that the engine idles roughly or stalls If as specified inspect the timing belt component valve timing deviation If not as specif...

Page 370: ...RECHARGING G 5 GENERATOR REMOVAL INSTALLATION G 6 GENERATOR INSPECTION G 7 IGNITION SYSTEM G 8 IGNITION COIL REMOVAL INSTALLATION G 8 IGNITION COIL INSPECTION G 9 SPARK PLUG REMOVAL INSTALLATION G 10...

Page 371: ...RY RECHARGING 2 Generator See G 6 GENERATOR REMOVAL INSTALLATION See G 7 GENERATOR INSPECTION 3 Starter See G 11 STARTER REMOVAL INSTALLATION See G 12 STARTER INSPECTION 4 Ignition coil See G 9 IGNITI...

Page 372: ...INSTALLATION A6E471018520W01 1 Remove in the order indicated in the table 2 Install in the reverse order of removal End Of Sie CHARGING SYSTEM 1 Negative battery cable 2 Battery cable 3 Battery clamp...

Page 373: ...rent decreases Back up current 20 mA max Caution Operating electrical loads while measuring the back up current can damage the circuit tester End Of Sie Step Inspection Result Action 1 Measure open ci...

Page 374: ...ent it from overheating 2 The water level should come up about halfway on the battery 3 Remove the battery plugs while charging the battery 4 Keep water off the top of the battery Caution To prevent d...

Page 375: ...he generator duct and the generator heat insulator are installed securely 1 Disconnect the negative battery cable 2 Remove the under cover 3 Disconnect the joint shaft from the drive shaft RH R H D Se...

Page 376: ...the terminals shown in the table If not as specified repair or replace the generator as necessary Standard voltage Turn the following electrical loads on and verify that the voltage reading increases...

Page 377: ...t be 0 A End Of Sie IGNITION COIL REMOVAL INSTALLATION A6E471218110W01 1 Disconnect the negative battery cable 2 Remove the plug hole plate End Of Sie Engine speed rpm Terminal B current A L8 LF L3 1...

Page 378: ...nce between the following lead holes using an ohmmeter A and B B and C If not specified replace the ignition coil Specification 0 49 0 57 ohms 20 C 68 F Secondary Coil Winding 1 Remove the ignition co...

Page 379: ...tion coil Specification Above 10 Megohm End Of Sie SPARK PLUG REMOVAL INSTALLATION A6E471218110W03 1 Disconnect the negative battery cable 2 Remove the plug hoie plate Lift off and remove the plug hol...

Page 380: ...nnect the negative battery cable End Of Sie SPARK PLUG INSPECTION A6E471218110W04 Caution Do not inspect adjust or clean the plug gap with a wire brush Doing so can damage the platinum tip When cleani...

Page 381: ...disconnect the battery negative cables before performing the following operation 1 Disconnect the negative battery cable 2 Remove the under cover 3 Remove the air cleaner assembly See F 10 INTAKE AIR...

Page 382: ...inspect the magnetic switch and the starter Inspect the related wiring harness and the ignition switch No Load Test 1 Verify that the battery is fully charged 2 Connect the starter battery voltmeter a...

Page 383: ...LATION H 6 CLUTCH MASTER CYLINDER H 7 CLUTCH MASTER CYLINDER REMOVAL INSTALLATION H 7 CLUTCH MASTER CYLINDER DISASSEMBLY ASSEMBLY H 8 CLUTCH RELEASE CYLINDER H 9 CLUTCH RELEASE CYLINDER REMOVAL INSTAL...

Page 384: ...ION 2 Clutch master cylinder See H 7 CLUTCH MASTER CYLINDER REMOVAL INSTALLATION See H 8 CLUTCH MASTER CYLINDER DISASSEMBLY ASSEMBLY 3 Clutch release cylinder See H 9 CLUTCH RELEASE CYLINDER REMOVAL I...

Page 385: ...fluid bleed the air and inspect for leakage after the procedure has been completed 2 Remove the clutch pipe using the SST 49 0259 770B Install the clutch pipe using torque wrench SST combination See G...

Page 386: ...under cover 2 Draw the fluid from the reservoir with a suction pump 3 Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug 4 Place the other end of the...

Page 387: ...nce is felt and measure the pedal free play If not as specified adjust the pedal free play by loosening locknut C and turning push rod D as necessary Pedal free play 1 0 3 0 mm 0 04 0 11 in Push rod f...

Page 388: ...free play to specification Clutch pedal disengagement stroke Minimum 20 mm 0 79 in Reference value Pedal stroke 140 0 mm 5 51 in Reference value End Of Sie CLUTCH PEDAL REMOVAL INSTALLATION A6E491441...

Page 389: ...STALLATION A6E491641990W01 1 Remove the battery and battry tray European L H D GCC specs 2 Remove in the order indicated in the table 3 Plug the clutch pipe after removing it to avoid leakage 4 Instal...

Page 390: ...Snap Ring Disassembly Assembly Note 1 Hold the piston down using a cloth wrapped pin punch If disassembling remove the snap ring if assembling install it End Of Sie A6E4916W002 1 Clip 2 Hose 3 Joint 4...

Page 391: ...INDER REMOVAL INSTALLATION A6E491841920W01 1 Remove the under cover 2 Remove in the order indicated in the table 3 Install in the reverse order of removal End Of Sie CLUTCH RELEASE CYLINDER A6E4918W00...

Page 392: ...SSEMBLY ASSEMBLY A6E491841920W02 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly End Of Sie A6E4918W002 1 Boot 2 Push rod 3 Piston and cap 4 Return spr...

Page 393: ...inder 2 Manual transaxle See J 5 MANUAL TRANSAXLE REMOVAL INSTALLATION 3 Boot 4 Clutch release collar 5 Clutch release fork 6 Clutch cover See H 12 Clutch Cover and Disc Removal Note See H 13 Clutch C...

Page 394: ...n a crisscross pattern 3 Remove the flywheel Flywheel Installation Note 1 Install the flywheel to the crankshaft 2 When reusing the bolts clean threads and hole then apply locking compound to the thre...

Page 395: ...Of Sie CLUTCH COVER INSPECTION A6E492016410W01 1 Measure the wear of the diaphragm spring fingers If not as specified replace the clutch cover Depth 0 6 mm 0 024 in max 2 Measure the flatness of the...

Page 396: ...minimum Thickness 0 3 mm 0 012 in min 2 Measure the clutch disc runout using a dial indicator If the runout is excessive replace the clutch disc Runout 0 7 mm 0 028 in max End Of Sie CLUTCH RELEASE C...

Page 397: ...PECTION A6E492211500W01 1 Install a dial gauge on the cylinder block 2 Measure the flywheel runout using a dial indicator If the runout is excessive replace the flywheel Runout 0 1 mm 0 004 in max End...

Page 398: ...3 TRANSAXLE OIL INSPECTION J 3 TRANSAXLE OIL REPLACEMENT J 3 OIL SEAL DIFFERENTIAL REPLACEMENT J 4 VEHICLE SPEEDOMETER SENSOR REMOVAL INSTALLATION J 4 VEHICLE SPEEDOMETER SENSOR INSPECTION J 5 MANUAL...

Page 399: ...AL REPLACEMENT 2 Vehicle speedometer sensor See J 4 VEHICLE SPEEDOMETER SENSOR REMOVAL INSTALLATION See J 5 VEHICLE SPEEDOMETER SENSOR INSPECTION 3 Manual transaxle See J 5 MANUAL TRANSAXLE REMOVAL IN...

Page 400: ...f m 29 43 ft lbf End Of Sie TRANSAXLE OIL REPLACEMENT A6E511227001W02 1 Remove the drain plug with the washer 2 Drain the oil into a suitable container 3 Install a new washer and the drain plug Tighte...

Page 401: ...ATION 9 Install the wheels and splash shields 10 Add the specified amount and type of oil See J 3 TRANSAXLE OIL REPLACEMENT End Of Sie VEHICLE SPEEDOMETER SENSOR REMOVAL INSTALLATION A6E511217400W01 W...

Page 402: ...ing pipe See N 10 STEERING GEAR AND LINKAGE REMOVAL INSTALLATION 6 Remove the front auto leveling sensor See T 32 FRONT AUTO LEVELING SENSOR REMOVAL INSTALLATION 7 Drain the transaxle oil into a suita...

Page 403: ...J 6 MANUAL TRANSAXLE A6E5112W012 1 O2 sensor connector 2 Back up light switch connector 3 Neutral switch connector 4 Harness bracket 5 Vehicle speedometer sensor connector GCC specs...

Page 404: ...ilizer control link 15 Damper fork 16 Lower arm front rear ball joint See R 19 Front Lower Arm Rear Ball Joint Removal Note See R 16 Front Lower Arm Front Ball Joint Removal Note 17 Drive shaft See M...

Page 405: ...ine mount bracket to the transaxle 3 By aligning the holes with the stud bolts install the No 1 engine mount to the transaxle 4 Align the hole of the No 4 engine mount bracket with the No 4 engine mou...

Page 406: ...See U 44 CLIMATE CONTROL UNIT REMOVAL See U 45 CLIMATE CONTROL UNIT INSTALLATION 6 Remove the rear heat duct See U 23 REAR HEAT DUCT REMOVAL INSTALLATION 7 Remove in the order indicated in the table...

Page 407: ...shift lever side in the order shown in the figure 4 Shift the sift lever to neutral 5 Lock the lock pice of the selector cable shift cable side in the order shown in the figure 6 Install the center co...

Page 408: ...ATE REMOVAL INSTALLATION K 43 AUTOMATIC TRANSAXLE SHIFT MECHANISM K 45 SHIFT LOCK INSPECTION K 45 KEY INTERLOCK INSPECTION K 45 INTERLOCK CABLE INSPECTION K 45 INTERLOCK CABLE ADJUSTMENT K 46 SELECTOR...

Page 409: ...EXCESSIVE SHIFT SHOCK IS FELT WHEN UPSHIFTING AND DOWNSHIFTING K 127 NO 19 EXCESSIVE SHIFT SHOCK ON TORQUE CONVERTER CLUTCH TCC K 127 NO 20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIO...

Page 410: ...K 3 K...

Page 411: ...K 4 LOCATION INDEX AUTOMATIC TRANSAXLE LOCATION INDEX A6E560001074W01 LOCATION INDEX A6E5600W001...

Page 412: ...lve See K 26 SOLENOID VALVE INSPECTION See K 28 SOLENOID VALVE REMOVAL INSTALLATION 8 PCM See K 29 PCM INSPECTION See K 29 PCM REMOVAL INSTALLATION 9 Automatic transaxle See K 29 AUTOMATIC TRANSAXLE R...

Page 413: ...ne pressure at idle engine speed for the D HOLD S S HOLD L L HOLD ranges and R positions in the same manner as in Steps 4 5 7 Stop the engine then replace the SST 49 B019 901B with the gauge of the SS...

Page 414: ...ator pedal 7 Shift the selector lever to N position and let the engine idle for 1 minute or more to cool the ATF 8 Perform a stall test of D HOLD S S HOLD L L HOLD and R range positions in the same ma...

Page 415: ...ake band slippage In L range and R position Low and reverse brake slippage In R position Low and reverse brake slippage Reverse clutch slipping Perform road test to determine whether problem is low an...

Page 416: ...See K 9 Road Test Preparation 2 Shift the selector lever to D range 3 Accelerate the vehicle with half and WOT then verify that 1 2 2 3 and 3 4 upshifts can be obtained The shift points must be as sh...

Page 417: ...nt is as shown in the table below If not as specified inspect the PCM and ATX See K 113 SYMPTOM TROUBLESHOOTING ITEM TABLE 5 Decelerate the vehicle and verify that engine braking effect is felt in 2GR...

Page 418: ...and ATX See K 113 SYMPTOM TROUBLESHOOTING ITEM TABLE 6 Select HOLD mode 7 Accelerate the vehicle in 1GR at half throttle and WOT and verify that 1GR is held If not as specified inspect the PCM and ATX...

Page 419: ...ngine In this case use the cool range 15 25 C 59 77 F 4 Warm up the engine until the ATF reaches 60 70 C 140 158 F 5 Shift the selector lever and pause momentarily in each range D L while depressing t...

Page 420: ...e ATF type ATF M V 6 Ensure that the ATF level is in the HOT range 65 C 149 F Add ATF to the specified level as necessary End Of Sie HOLD SWITCH INSPECTION A6E561446030W01 Operating Inspection 1 Turn...

Page 421: ...ver knob component 7 Install selector lever knob component Tightening torque 15 68 22 54 N m 1 599 2 298 kgf m 12 16 ft lbf 8 Install the HOLD switch terminals and connect the connector 9 Install the...

Page 422: ...ALLATION A6E561419440W02 1 Disconnect the negative battery cable 2 Remove the air cleaner component See F 10 INTAKE AIR SYSTEM REMOVAL INSTALLATION Caution Water or foreign objects entering the connec...

Page 423: ...ousing side fully then return 2 notches to set the N position 10 Turn the protrusion at resistance between the terminals B and C become 750 ohms 11 Install the TR switch while aligning the protrusion...

Page 424: ...act wrench Hold the manual shaft lever when removing the manual shaft nut or the transaxle may be damaged 15 Install the manual shaft lever and the washer 16 Set the adjustable wrench as shown to hold...

Page 425: ...cified readjust the TR switch See K 18 TRANSAXLE RANGE TR SWITCH ADJUSTMENT End Of Sie TRANSAXLE RANGE TR SWITCH ADJUSTMENT A6E561419440W03 1 Disconnect the negative battery cable 2 Remove the air cle...

Page 426: ...aft lever as shown in the figure 15 Inspect operation of the TR switch See K 14 TRANSAXLE RANGE TR SWITCH INSPECTION If not as specified readjust the TR switch 16 Install the air cleaner component See...

Page 427: ...When the transaxle and ATF are hot they can badly burn Turn off the engine and wait until they are cool before replacing ATF 1 Remove the control valve body See K 34 CONTROL VALVE BODY REMOVAL 2 Remo...

Page 428: ...n See K 34 CONTROL VALVE BODY REMOVAL 2 Disconnect the TFT sensor connector 3 Remove the TFT sensor 4 Install a TFT sensor 5 Connect the TFT sensor connector 6 Install the oil pan See K 35 CONTROL VAL...

Page 429: ...ure switch inspection 1 Remove the under cover 2 Disconnect the cord assembly connector 3 Start the engine with gear position in N or P 4 Reaffirm that there is no continuity between cord assembly ter...

Page 430: ...e 2 Remove the under cover 3 Disconnect the cord assembly connector 4 Remove the oil pressure switch 5 Install the oil pressure switch Tightening torque 17 1 22 1N m 1 75 2 25kgf m 13 16ft lbf 6 Conne...

Page 431: ...n a new input turbine speed sensor 7 Install the input turbine speed sensor Tightening torque 8 11 N m 82 112 kgf cm 71 97 in lbf 8 Connect the input turbine speed sensor connector 9 Install the air c...

Page 432: ...S connector terminal C to GND If an open circuit or short circuit is found repair the malfunctioning wiring harness If there are no open or short circuits perform the sensor rotor inspection Short Cir...

Page 433: ...O ring and install it on a new VSS 6 Install the VSS Tightening torque 8 11 N m 82 112 kgf cm 71 97 in lbf 7 Connect the VSS connector 8 Install the under cover 9 Connect the negative battery cable En...

Page 434: ...is okay perform the resistance inspection off vehicle inspection If there is a problem repair or replace the transaxle harness 3 Apply battery positive voltage to terminal D and battery negative volta...

Page 435: ...D E Resistance 10 9 26 2 ohms ATF temperature 40 150 C 40 302 F End Of Sie SOLENOID VALVE REMOVAL INSTALLATION A6E561421280W02 1 Disconnect the negative battery cable 2 Remove the under cover 3 Remove...

Page 436: ...4 Remove the front tires and splash shield 5 Remove the under cover 6 Remove the steering gear and power steering pipe See N 10 STEERING GEAR AND LINKAGE REMOVAL INSTALLATION 7 Remove the front auto...

Page 437: ...K 30 AUTOMATIC TRANSAXLE A6E5614W046 1 O2 sensor connector 2 Oil pressure switch connector for oil filter 3 Oil pressure switch connector for ATX 4 Input turbin speed sensor connector...

Page 438: ...joint See R 19 Front Lower Arm Rear Ball Joint Removal Note See R 16 Front Lower Arm Front Ball Joint Removal Note 19 Drive shaft See M 17 DRIVE SHAFT REMOVAL INSTALLATION 20 Drive shaft See M 17 DRIV...

Page 439: ...t 2 Install the transaxle mounting bolts Tightening torque 37 3 52 N m 3 8 5 3 kgf m 28 38 ft lbf Torque Converter Nuts Removal Note 1 Hold the cankshaft pulley to prevent drive plate from rotating 2...

Page 440: ...engine mount bracket to the transaxle 3 By aligning the holes with the stud bolts install the No 1 engine mount to the transaxle 4 Align the hole of the No 4 engine mount bracket with the No 4 engine...

Page 441: ...particles to fly out causing injury to the eyes Wear protective eyes whenever using compressed air Caution Clean the transaxle exterior throughout with a steam cleaner or cleaning solvents before remo...

Page 442: ...springs and accumulators into the transaxle case A6E5614W059 Spring Outer diameter mm in Free Length mm in No of coils Wire diameter mm in Servo apply accumulator large spring 21 0 0 827 67 8 2 669 10...

Page 443: ...mber See R 23 FRONT CROSSMEMBER REMOVAL INSTALLATION 9 Install the front tires and splash shield 10 Install the under cover 11 Connect the negative battery cable 12 Add ATF and with the engine idling...

Page 444: ...is ventilation carry out the following steps 1 Remove the oil pan and inspect the fluid filter element from the front filter 2 If the element is covered with too much debris or particles and cannot be...

Page 445: ...s pinched cracks or any other damage before reusing them If any problems exist replace lines and clamps Caution Always use new clamps when replacing hoses Back flushing 1 Using the power flushing equi...

Page 446: ...ENT 7 Connect the negative battery cable 8 Inspect for oil leakage from the oil pipes and oil hoses 9 Inspect for coolant from the hoses 10 Inspect the ATF level and condition See K 12 AUTOMATIC TRANS...

Page 447: ...e 2 Follow the instructions in the manufacturer s publication for flushing operation Oil Pipe Hose Clamp Oil Hose Installation Note 1 Apply compressed air to cooler side opening and blow any remaining...

Page 448: ...stall the new hose clamp onto the hose 4 Verify that the hose clamp does not interfere with any other components End Of Sie OIL COOLER DISASSEMBLY ASSEMBLY A6E561419900W03 1 Disassemble in the order i...

Page 449: ...is clean and free of foreign material or damage 6 Inspect the radiator outer tank for warping If it is warped replace radiator tank Radiator Outer Tank In Tank Oil Cooler Installation Note 1 Install a...

Page 450: ...ect for leakage from radiator See E 4 ENGINE COOLANT LEAKAGE INSPECTION End Of Sie DRIVE PLATE REMOVAL INSTALLATION A6E561419020W01 1 Remove the transaxle See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLA...

Page 451: ...bolt replace the bolts Do not apply sealant if a new bolts is used 2 Install the drive plate 3 Install the adapter 4 Apply sealant to the drive plate mounting bolts and install them 5 Set the SST or...

Page 452: ...gnition key cannot be pulled out except in P position If a malfunction is found inspect the interlock cable See K 45 INTERLOCK CABLE INSPECTION End Of Sie INTERLOCK CABLE INSPECTION A6E561609000W02 1...

Page 453: ...of the selector lever base plate then remove the interlock cable from the U groove 4 Remove the interlock cable from the selector lever 5 Fully pull the end of the interlock cable to the selector leve...

Page 454: ...brake switch connector until the interlock cable adjustment is completed 13 Install the lock unit to the bracket See K 49 Interlock Cable Installation Note 14 Rotate the slider pin to release the loc...

Page 455: ...connector Once the brake switch clearance has automatically been adjusted it cannot be adjusted again Therefore replace the switch with a new one when replacing the power brake unit or the pedal or p...

Page 456: ...area to interfere with the lever End Of Sie SELECTOR LEVER REMOVAL INSTALLATION A6E561646102W03 1 Disconnect the negative battery cable 2 Remove battery and battery tray 3 Remove the air cleaner comp...

Page 457: ...TRANSAXLE SHIFT MECHANISM A6E5616W005 1 Column cover with key interlock 2 Clip with key interlock 3 Clip with key interlock 4 Interlock cable with key interlock See K 49 Interlock Cable Installation N...

Page 458: ...he selector lever certainly 2 Install the selector cable to the bracket certainly Note Step 3 4 is for the selector cable replacement only 3 Verify that the selector lever is in P position 4 Lock the...

Page 459: ...ther position the interlock cable to pass over the selector cable 2 Push the snap pin or a 1 5 round bar or simular into hole A by fully pushing the slider pin in 3 Push the snap pin into hole B and h...

Page 460: ...the interlock cable in the U groove in the selector lever base plate and install the clip 13 Press the interlock cable lock piece in until it is locked Caution Applying a load to the interlock cable w...

Page 461: ...s connected before installation the clearance may be incorrect causing a brake light malfunction Therefore always verify that the brake switch is properly installed before connecting the connector Onc...

Page 462: ...bly Connector Disassembly Note 1 Insert a thin piece of metal from the terminal side of the connector and press down the terminal locking tab 2 Pull the terminal out of the connector End Of Sie AUTOMA...

Page 463: ...T End Of Sie AFTER REPAIR PROCEDURE A6E567001030W03 Caution After repairing a malfunction perform this procedure to verify that the malfunction has been corrected When this procedure is carried out be...

Page 464: ...circuit high input See F 67 DTC TABLE P0125 Excessive time to enter closed loop fuel control See F 67 DTC TABLE P0131 Front HO2S no inversion low stuck See F 67 DTC TABLE P0132 Front HO2S no inversion...

Page 465: ...tion short to ground ON YES 1 CCM See K 64 DTC P0712 P0713 Transaxle fluid temperature TFT sensor circuit malfunction open circuit ON YES 1 CCM See K 65 DTC P0713 P0715 Input turbine speed sensor circ...

Page 466: ...overcharge See F 67 DTC TABLE P2504 Generator terminal B circuit open See F 67 DTC TABLE U0073 CAN bus off See F 67 DTC TABLE U0121 PCM cannot receive any signals from ABS ABS TCS or DSC HU CM See F 6...

Page 467: ...to OFF Disconnect VSS connector Check for poor connection damaged pulled out terminals corrosion etc Is connection okay Yes Go to next step No Repair or replace pin or connector then go to Step 10 4 I...

Page 468: ...WDS or equivalent Warm up engine Drive vehicle under following conditions for 4 5 seconds or more while monitoring PIDs Engine coolant temp 60 C 140 F or above Drive in L range Frequency of input tur...

Page 469: ...ivalent Drive vehicle in each range D S L and R for 100 seconds or more under following conditions Engine speed RPM PID 530 rpm or above Vehicle speed VSS PID 20 km h 12 mph or above Is pending code p...

Page 470: ...No Go to next step 3 INSPECT TR SWITCH CONNECTOR Turn ignition key OFF Disconnect TR switch connector Inspect for bent terminals of TR switch terminals B and C part side Are TR switch terminals okay...

Page 471: ...m h 12 mph or above Is pending code present Yes Replace PCM then go to next step See F 43 PCM REMOVAL INSTALLATION No No concern is detected Go to next step 9 VERIFY AFTER REPAIR PROCEDURE Perform Aft...

Page 472: ...ted repair information available Yes Perform repair or diagnosis according to available repair information If vehicle is not repaired go to next step No Go to next step 3 INSPECT TR SWITCH CONNECTOR F...

Page 473: ...CH SIGNAL CIRCUIT FOR OPEN CIRCUIT Check for continuity between TR switch terminal C harness side and PCM terminal 1W Is there continuity Yes Go to next step No Repair or replace harness for open then...

Page 474: ...availability Is any related repair information available Yes Perform repair or diagnosis according to available repair information If vehicle is not repaired go to next step No Go to next step 3 INSPE...

Page 475: ...es DTC is stored in the PCM memory POSSIBLE CAUSE TFT sensor malfunction Short to ground between TFT sensor terminal A and ATX connector terminal E Short to ground between TFT sensor terminal B and AT...

Page 476: ...s Repair or replace harness then go to Step 9 No Replace TFT sensor then go to step 9 See K 21 TRANSAXLE FLUID TEMPERATURE TFT SENSOR REMOVAL INSTALLATION 8 INSPECT ATX CONNECTOR CIRCUIT FOR SHORT TO...

Page 477: ...ins availability Is any related repair information available Yes Perform repair or diagnosis according to available repair information If vehicle is not repaired go to next step No Go to next step 3 V...

Page 478: ...p 11 8 INSPECT PCM CONNECTOR FOR POOR CONNECTION Turn ignition key to OFF Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Is connection okay Yes Go to nex...

Page 479: ...n Short to ground between input turbine speed sensor terminal A and PCM terminal 3J Short to ground between input turbine speed sensor terminal B and PCM terminal 3G Open circuit between input turbine...

Page 480: ...ne speed sensor See K 24 INPUT TURBINE SPEED SENSOR REMOVAL INSTALLATION Yes Clean input turbine speed sensor then go to Step 10 No Go to next step 7 INSPECT PCM CONNECTOR FOR POOR CONNECTION Disconne...

Page 481: ...ve stuck Oil pump PCM malfunction STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Bulletins availability Is any related repair information available Y...

Page 482: ...range 1st gear Throttle opening angle TP PID 5 67 or above Vehicle speed VSS PID 4 km h 3 mph or above Are any DTCs present Yes Replace PCM then go to next step No Go to next step 9 VERIFY AFTER REPAI...

Page 483: ...uld not hear click sound then go to Step 8 See K 28 SOLENOID VALVE REMOVAL INSTALLATION 5 INSPECT LINE PRESSURE Start engine Measure line pressures Specification Idle 330 470 kPa 3 4 4 7 kgf cm2 49 66...

Page 484: ...20 C 68 F or above Driving in 3 GR in D range Engine run Turbine speed within 225 4 988 rpm Differential gear case output revolution speed 35 rpm or above Any of the following not generated DTC P0500...

Page 485: ...ification 2 000 2 600 rpm Is stall speed within specification Yes Go to next step No Replace automatic transaxle then go to Step 8 See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION 7 INSPECT FREQUENCY...

Page 486: ...eriorated ATF Shift solenoids A B or C stuck Pressure control solenoid stuck Line pressure low 2 4 brake band slipping 3 4 clutch slipping Forward clutch slipping Control valve stuck Bypass or 3 4 shi...

Page 487: ...engine Measure frequency of input turbine speed sensor while driving vehicle under the following conditions Vehicle speed VSS PID 80 km h 49 mph Drive in D range 4th gear Throttle opening angle TP PI...

Page 488: ...TION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Bulletins availability Is any related repair information available Yes Perform repair or diagnosis according to availabl...

Page 489: ...IR PROCEDURE Perform After Repair Procedure See K 52 AFTER REPAIR PROCEDURE Are any DTCs present Yes Go to applicable DTC inspection No Troubleshooting completed STEP INSPECTION ACTION DTC P0742 Torqu...

Page 490: ...Any ranges Replace ATX then go to Step 6 See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION See ATX Workshop Manual FN4A EL 9999 95 FN4A 99 5 CHECK OPERATION OF EACH VALVE AND EACH SPRING Turn ignitio...

Page 491: ...ntinuous monitor CCM MIL does not illuminate if PCM detects above malfunction conditions during first drive cycle PENDING CODE is not available FREEZE FRAME DATA is not available HOLD indicator light...

Page 492: ...rol solenoid terminals A and B Is resistance within 2 4 7 3 ohms See K 27 Resistance Inspection Off Vehicle Inspection Yes Replace solenoid harness then go to Step 10 No Verify pressure control soleno...

Page 493: ...nates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM PENDING CODE is available i...

Page 494: ...der the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATF temperature 20 C 68 F or above Drive in D range Is pending code present Yes Replace PCM then go to next step Se...

Page 495: ...pecification See K 6 Line Pressure Test Yes Go to next step No All ranges Replace oil pump or control valve body then go to Step 7 Any ranges Replace ATX then go to Step 7 See K 29 AUTOMATIC TRANSAXLE...

Page 496: ...above malfunction conditions during first drive cycle PENDING CODE is not available FREEZE FRAME DATA is available HOLD indicator light flashes DTC is stored in the PCM memory POSSIBLE CAUSE Shift sol...

Page 497: ...ep No Repair or replace connector and or terminal then go to Step 11 6 INSPECT RESISTANCE Inspect resistance between shift solenoid A terminals A and B part side Is resistance within 1 0 4 2 ohms See...

Page 498: ...illuminates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM PENDING CODE is avai...

Page 499: ...o next step See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION See ATX Workshop Manual FN4A EL 9999 95 FN4A 99 No Repair or replace shift valve and return spring then go to next step See K 34 CONTROL V...

Page 500: ...onitor CCM MIL illuminates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM PENDIN...

Page 501: ...FN4A 99 7 VERIFY TROUBLESHOOTING OF DTC P0757 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using WDS or equivalent Start engine Warm up ATX Drive the vehicle und...

Page 502: ...RAME DATA HAS BEEN RECORDED Has FREEZE FRAME PID DATA been recorded Yes Go to next step No Record FREEZE FRAME PID DATA on repair order then go to next step 2 VERIFY RELATED REPAIR INFORMATION AVAILAB...

Page 503: ...or and or terminals then go to Step 11 8 INSPECT ATX CONNECTOR CIRCUIT FOR OPEN Inspect for continuity between PCM terminal 4AC harness side and ATX connector terminal C vehicle harness side Is there...

Page 504: ...illuminates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM PENDING CODE is avail...

Page 505: ...place ATX then go to next step See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION See ATX Workshop Manual FN4A EL 9999 95 FN4A 99 No Repair or replace shift valve and return spring then go to next step...

Page 506: ...onitor CCM MIL illuminates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM PENDIN...

Page 507: ...ng conditions and make sure that gears shift smoothly from 1GR to 4GR ATF temperature 20 C 68 F or above Drive in D range Throttle opening angle TP PID 0 4GR only Vehicle speed VSS PID 50 km h 31 mph...

Page 508: ...able repair information If vehicle is not repaired go to next step No Go to next step 3 INSPECT ATX CONNECTOR FOR POOR CONNECTION Turn ignition key to OFF Disconnect ATX connector Check for poor conne...

Page 509: ...rminal 4Y harness side and ATX connector terminal G vehicle harness side Is there continuity between terminals Yes Go to next step No Repair or replace harness then go to Step 11 9 INSPECT ATX CONNECT...

Page 510: ...ECTION ACTION 1 VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Has FREEZE FRAME PID DATA been recorded Yes Go to next step No Record FREEZE FRAME PID DATA on repair order then go to next step 2 VERIFY REL...

Page 511: ...REMOVAL INSTALLATION No Go to next step 8 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K 52 AFTER REPAIR PROCEDURE Are any DTCs present Yes Go to applicable DTC inspection No Troub...

Page 512: ...specification See K 6 Line Pressure Test Yes Go to next step No All ranges Replace oil pump or control valve body then go to Step 7 Any ranges Replace ATX then go to Step 7 See K 29 AUTOMATIC TRANSAXL...

Page 513: ...first drive cycle PENDING CODE is not available FREEZE FRAME DATA is available HOLD indicator light flashes DTC is stored in the PCM memory POSSIBLE CAUSE Shift solenoid D malfunction Short to ground...

Page 514: ...ce solenoid then go to Step 11 See K 28 SOLENOID VALVE REMOVAL INSTALLATION 7 INSPECT PCM CONNECTOR FOR POOR CONNECTION Disconnect PCM connector Check for poor connection damaged pulled out terminals...

Page 515: ...EN RECORDED Has FREEZE FRAME PID DATA been recorded Yes Go to next step No Record FREEZE FRAME PID DATA on repair order then go to next step 2 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for...

Page 516: ...ROCEDURE Perform After Repair Procedure See K 52 AFTER REPAIR PROCEDURE Are any DTCs present Yes Go to applicable DTC inspection No Troubleshooting completed STEP INSPECTION ACTION DTC P0772 Shift sol...

Page 517: ...essure Test Yes Go to next step No All ranges Replace oil pump or control valve body then go to Step 7 Any ranges Replace ATX then go to Step 7 See K 29 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION See AT...

Page 518: ...PCM memory POSSIBLE CAUSE Shift solenoid E malfunction Short to ground between ATX connector terminal F and PCM terminal 3P Short to power between ATX connector terminal F and PCM terminal 3P Open ci...

Page 519: ...ctor Check for poor connection damaged pulled out terminals corrosion etc Is connection okay Yes Go to next step No Repair or replace connector and or terminals then go to Step 11 8 INSPECT ATX CONNEC...

Page 520: ...se revolution below 0 64 or more than 0 82 Any of the following not generated DTC P0500 P0706 P0707 P0708 P0712 P0713 P0715 P0751 P0752 P0753 P0756 P0757 P0758 P0761 P0762 P0763 P0766 P0767 P0768 P077...

Page 521: ...CH REMOVAL INSTALLATION No Go to next step 4 INSPECT PCM CONNECTOR FOR POOR CONNECTION Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Is connection okay...

Page 522: ...transaxle fluid temperature Inspect TFT sensor See K 19 TRANSAXLE FLUID TEMPERATURE TFT SENSOR INSPECTION 3D TFTV Transaxle fluid signal voltage V ATF 20 C 68 F 3 4 3 6 V ATF 130 C 266 F 0 4 0 5 V In...

Page 523: ...SPECTION See K 14 TRANSAXLE RANGE TR SWITCH INSPECTION If selector lever and TR switch are okay go to next step 3 Inspect ATF color and condition See K 12 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Are...

Page 524: ...ugh accelerator pedal is released in D range at 60 km h 37 mph See K 120 NO 8 DOES NOT SHIFT TO FOURTH GEAR 4GR 9 Abnormal shifting Shifts incorrectly incorrect shift pattern See K 122 NO 9 ABNORMAL S...

Page 525: ...ehicle coasts when accelerator pedal is released when in L range at low vehicle speed See K 129 NO 22 NO ENGINE BRAKING IN HOLD MODE 23 Transaxle overheats Burnt smell emitted from transaxle Smoke is...

Page 526: ...TROUBLESHOOTING K 115 K QUICK DIAGNOSIS CHART A6E568001030W04 A6E5680W001...

Page 527: ...K 116 TROUBLESHOOTING End Of Sie A6E5680W002...

Page 528: ...Go to next step No Check for parking mechanism See ATX workshop manual FN4A EL 1623 10 98E See ATX workshop manual supplement FN4A EL 1746 1 02C 2 Disconnect PCM Is resistance between ground terminal...

Page 529: ...2 Improper adjustment of selector lever 3 If vehicle moves in N position perform No 2 Vehicle moves in N position 4 Excessive creep DESCRIPTION Vehicle accelerates in D S L ranges and R position witho...

Page 530: ...t solenoid C malfunction Pressure control solenoid malfunction Body GND malfunction Control valve body malfunction 2 Signal malfunction Vehicle speed sensor malfunction Sensor GND malfunction TP senso...

Page 531: ...f malfunction No Overhaul transaxle and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E See ATX workshop manual supplement FN4A EL 1746 1 02C STEP INSPECTION ACTION 7...

Page 532: ...tion Note Before following troubleshooting steps make sure that Automatic Transaxle On Board Diagnostic and Automatic Transaxle Basic Inspection are conducted STEP INSPECTION ACTION 1 With indicator s...

Page 533: ...n 5 0 ohms Yes Go to next step No Repair open ground circuit Reconnect PCM 2 Check the value at the following PIDs using the WDS or equivalent See 3940 PCM INSPECTION TP TSS VSS Is PID value okay Yes...

Page 534: ...Yes Go to next step No Go to No 26 HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON No 27 HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED ON 2 Check the value at...

Page 535: ...witch position disparity Note Before following troubleshooting steps make sure that Automatic Transaxle On Board Diagnostic and Automatic Transaxle Basic Inspection are conducted STEP INSPECTION ACTIO...

Page 536: ...WDS or equivalent See F 45 PCM INSPECTION TSS Are PID values okay Yes Go to next step No Repair or replace any defective parts 2 Disconnect PCM Is resistance between ground terminal at PCM connector a...

Page 537: ...1 Does shift shock occur only when engine cold Yes Go to next step No Go to Step 3 2 Disconnect PCM Is resistance between ground terminal at PCM connector and body ground less than 5 0 ohms Yes Check...

Page 538: ...urbine speed sensor malfunction 3 Poor hydraulic operation Malfunction in range change Pressure switch malfunction Forward accumulator malfunction Servo apply accumulator malfunction Note Before follo...

Page 539: ...p No Overhaul control valve body and repair or replace any defective parts If problem remains overhaul transaxle and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E S...

Page 540: ...om troubleshooting NO 14 Engine flares up or slips when upshifting or downshifting or No 15 Engine flares up or slips when accelerating vehicle No Repeat basic inspection and repair or replace any def...

Page 541: ...ALLS DURING DECELERATION Is engine control system okay Yes Repeat basic inspection and repair or replace any defective parts according to inspection result See K 112 BASIC INSPECTION No Repair or repl...

Page 542: ...s HOLD indicator light okay Yes Inspect for open circuit or disconnected connector in harness between the following Ignition switch and HOLD indicator light HOLD indicator light and PCM No Repair or r...

Page 543: ...REPLACEMENT M 4 WHEEL HUB STEERING KNUCKLE REMOVAL INSTALLATION M 5 REAR AXLE M 9 WHEEL HUB HUB SPINDLE PRE INSPECTION M 9 WHEEL HUB HUB SPINDLE REMOVAL INSTALLATION M 10 DRIVE SHAFT M 12 JOINT SHAFT...

Page 544: ...TEERING KNUCKLE PRE INSPECTION See M 5 WHEEL HUB STEERING KNUCKLE REMOVAL INSTALLATION 3 Joint shaft See M 12 JOINT SHAFT PRE INSPECTION See M 12 JOINT SHAFT REMOVAL INSTALLATION See M 14 JOINT SHAFT...

Page 545: ...9 770B Be sure to modify the brake pipe flare nut tightening torque to allow for use of a torque wrench SST combination See GI 16 TORQUE FORMULAS 2 If any brake line has been disconnected any time dur...

Page 546: ...ied torque and retest Replace the wheel bearing as necessary End Of Sie WHEEL HUB BOLT REPLACEMENT A6E631233060W01 1 Remove the hub bolt using the SSTs Note If the dust cover interferes with the wheel...

Page 547: ...See M 9 Locknut Installation Note 2 Brake caliper component 3 Disc plate See P 20 Disc Plate Removal Note 4 Tie rod end ball joint See N 11 Tie rod End Ball Joint Removal Note 5 Bolt 6 Front lower ar...

Page 548: ...ut Wheel Hub Component Removal Note 1 Remove the wheel hub component using the SSTs 2 If the bearing inner race remains on the front wheel hub component grind a section of the bearing inner race until...

Page 549: ...r and steering knuckle for proper installation 2 Remove the dust cover using a chisel Hub Bolt Removal Note Note The hub bolts do not need to be removed unless they are being replaced 1 Remove the hub...

Page 550: ...ign the marks of the new dust cover and the knuckle 3 Install the new dust cover using the SSTs Wheel Bearing Installation Note 1 Install the new wheel bearing using the SSTs Wheel Hub Component Insta...

Page 551: ...Position a dial indicator against the wheel hub 2 Push and pull the wheel hub by hand in the axial direction and measure the wheel bearing play Maximum wheel bearing play 0 05 mm 0 002 in 3 If the be...

Page 552: ...d in the table 2 Install in the reverse order of removal Locknut Removal Note 1 Knock the crimped portion of the locknut outward using a small cape chisel and a hammer 2 Lock the hub by applying the b...

Page 553: ...r rotor using a chisel ABS Sensor Rotor Installation Note Caution Position the SST so that marking B faces the bottom 1 Set the SST as shown in the figure 2 Press on the new sensor rotor using the SST...

Page 554: ...d sensor may possibly cause an open circuit in the harness if it is pulled by mistake Before performing the following procedures remove the ABS wheel speed sensor and fix it to an appropriate place wh...

Page 555: ...oint shaft is removed 1 Tie rod end ball joint See N 11 Tie rod End Ball Joint Removal Note 2 bolt 3 Lower arm front rear ball joint See R 15 FRONT LOWER ARM FRONT REMOVAL INSTALLATION See R 19 FRONT...

Page 556: ...1 23 in max End Of Sie JOINT SHAFT DISASSEMBLY ASSEMBLY A6E631625700W03 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly Joint Shaft Disassembly Note 1...

Page 557: ...e the bearing using the SSTs Dust Seal Right Assembly Note 1 Apply grease to the new dust seal lip 2 Install the new right side dust seal using the SSTs Bearing Assembly Note 1 Install the new bearing...

Page 558: ...ble the joint shaft using a press and the SST End Of Sie DRIVE SHAFT PRE INSPECTION A6E631625500W01 1 Inspect the dust boot on the drive shaft for cracks damage leaking grease and looseness in the boo...

Page 559: ...CEMENT 2 Remove in the order indicated in the table 3 Install in the reverse order of removal A6E0313W055 1 Locknut See M 6 Locknut Removal Note See M 9 Locknut Installation Note 2 Brake caliper compo...

Page 560: ...he left side drive shaft from the transaxle by prying with a bar inserted between the outer ring and the transaxle as shown in the figure 5 Install the SST into the transaxle to hold the side gears af...

Page 561: ...sembly A6E6316W003 A6E0313W043 1 Boot band wheel side See M 20 Boot Band Wheel Side Disassembly Note See M 23 Boot Band Wheel Side Assembly Note 2 Boot band transaxle side See M 20 Boot Band Transaxle...

Page 562: ...the locking clips using a screwdriver 2 Pull back the end of the band Outer Ring Disassembly Note 1 Mark the outer ring and the shaft for proper assembly 2 Remove the outer ring Snap Ring Tripod Join...

Page 563: ...Remove the boot ABS Sensor Rotor With ABS Disassembly Note Caution Do not remove the sensor rotor unless it is necessary Do not reuse the sensor rotor if removed 1 Tap the ABS sensor rotor off the dr...

Page 564: ...e the tape Tripod Joint Snap Ring Assembly Note 1 Align the marks and install the tripod joint using a bar and a hammer Caution Do not damage the roller 2 Install the new snap ring using snap ring pli...

Page 565: ...ust clearance A by turning the adjusting bolt of the SST Clearance A 2 9 mm 0 11 in 2 Crimp the wheel side small boot band using the SST Verify that clearance B is within the specification If clearanc...

Page 566: ...n the specification replace the boot band increase clearance A of the SST and crimp the new boot Clearance B 2 4 2 8 mm 0 095 0 110 in 8 Verify that the boot band does not protrude from the boot band...

Page 567: ...saxle Side Assembly Note 3 Clip See M 25 Clip Disassembly Note See M 26 Outer Ring Clip Assembly Note 4 Outer ring See M 26 Outer Ring Clip Assembly Note 5 Snap ring See M 26 Cage Inner Ring Balls Sna...

Page 568: ...e boot 3 Remove the tape Cage Inner Ring Balls Snap Ring Assembly Note 1 Align the marks and install the balls and cage to the inner ring in the direction shown in the figure Caution Install the cage...

Page 569: ...end of each boot with a cloth wrapped screwdriver Caution Be careful not to allow the grease to leak Do not damage the boot 7 Verify that the drive shaft length is within the specification End Of Sie...

Page 570: ...N N 4 STEERING WHEEL AND COLUMN INSPECTION N 6 STEERING WHEEL AND COLUMN REMOVAL INSTALLATION N 7 STEERING SHAFT INSPECTION N 9 STEERING GEAR AND LINKAGE REMOVAL INSTALLATION N 10 STEERING GEAR AND LI...

Page 571: ...NG WHEEL AND COLUMN REMOVAL INSTALLATION 3 Steering shaft See N 9 STEERING SHAFT INSPECTION 4 Steering gear and linkage See N 10 STEERING GEAR AND LINKAGE REMOVAL INSTALLATION See N 12 STEERING GEAR A...

Page 572: ...Removal Installation 1 Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and unloaded Note Unloaded Fuel tank is full Engine coolant and engine oil are a...

Page 573: ...re than 5 seconds the fluid temperature will rise excessively and adversely affect the oil pump 3 Inspect for fluid leakage If fluid leakage is found replace related pipe or hose Note The points where...

Page 574: ...nd increase the engine speed to 1 000 1 500 rpm 9 Turn the steering wheel fully to the left and right then measure the fluid pressure generated at the gear housing If the pressure is not within the sp...

Page 575: ...flection 2 With the vehicle on a hard level surface put the wheels in the straight ahead position 3 Remove the air bag module Warning See DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION for removal in...

Page 576: ...reverse order of removal 3 A6E0612W017 1 Air bag module See T 120 DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 2 Locknut 3 Steering wheel See N 8 Steering Wheel Removal Note See N 8 Steering Wheel...

Page 577: ...using a screwdriver 3 Disassemble the steering lock component Steering Lock Mounting Bolts Installation Note 1 Assemble the steering lock component to the steering shaft 2 Verify that the lock operat...

Page 578: ...e the steering shaft component as necessary Length 211 6 mm 8 3 in 2 Inspect the tilt and telescope operation 1 Verify that the adjusting lever moves smoothly from unlock position to lock position 2 V...

Page 579: ...not be pulled by mistake while servicing the vehicle 1 Remove in the order indicated in the table 2 Install in the reverse order of removal 3 After installation inspect the toe in See R 5 FRONT WHEEL...

Page 580: ...ge Removal Note L H D Caution Excessively loosening the crossmember nuts may possibly cause the crossmember to fall off The crossmember nuts must remain threaded on the studs when loosening 1 Support...

Page 581: ...s L H D Tightening torque Nut 119 6 154 8 N m 12 2 15 7 kgf m 89 114 ft lbf Bolt 93 1 131 3 N m 9 5 13 3 kgf m 69 96 ft lbf Bolt Intermediate Shaft Installation Note 1 Align the marks and install the...

Page 582: ...sing Component Disassembly Note 15 Pinion shaft component See N 14 Pinion Shaft Component Disassembly Note 16 O ring 17 Snap ring See N 14 Snap Ring Disassembly Note 18 Control valve component 19 Seal...

Page 583: ...and pull out the pinion shaft and housing component Pinion Shaft Component Disassembly Note Note If the pinion shaft does not come out easily remove it using a press 1 Push out the pinion shaft compo...

Page 584: ...ay the staked area by using a drill Caution Carefully pull out the holder without damaging the U gasket 2 Disassemble the holder Oil Seal Inner Guide Disassembly Note 1 Set the SSTs into the valve sid...

Page 585: ...nd a pull scale Rotation torque 0 4 2 7 N m 3 5 27 5 kgf cm 3 1 23 8 in lbf Pull scale reading 3 4 25 5 N 0 35 2 60 kgf 0 8 5 7 lbf 5 If not within the specification replace the tie rod end Tie rod In...

Page 586: ...8 Backup ring 9 U gasket 10 O ring 11 Holder See N 19 Holder Assembly Note 12 Oil seal See N 20 Oil Seal Assembly Note 13 Valve housing 14 Upper bearing See N 20 Upper Bearing Assembly Note 15 Pinion...

Page 587: ...e gear housing then press the mounting rubber until the mounting rubber end comes out completely from the other side At this time mounting rubber end and steel pipe are aligned Oil Seal Inner Guide As...

Page 588: ...ng rack to the gear housing press the oil seal and inner guide using the SSTs until the force required suddenly increases Holder Assembly Note 1 Apply grease to the U gasket and O ring 2 Assemble the...

Page 589: ...Assembly Note 1 Install a new seal ring to the valve part of the pinion shaft using the SST 2 After installing it seat it properly using the SST 3 Install the snap ring Adjusting Cover Assembly Note...

Page 590: ...e reading Less than 16 7 N 1 7 kgf 3 8 lbf 6 If not as specified repeat steps 2 through 5 7 Install the locknut using the SST 49 B032 320 Tightening torque 40 49 N m 4 1 4 9 kgf m 30 36 ft lbf Hermeti...

Page 591: ...ER STEERING OIL PUMP DISASSEMBLY ASSEMBLY A6E661432650W02 Note The following procedure is for replacement of the O ring and oil seal only Replace the pump component if other repairs are necessary 1 Di...

Page 592: ...5 Control valve 6 Spring 7 Clip See N 24 Clip Disassembly Note See N 24 Clip Assembly Note 8 Power steering reservoir tank 9 O ring 10 Rear pump body See N 25 Rear Pump Body Assembly Note 11 O ring 12...

Page 593: ...damage to the pump when securing it in a vise Clip Disassembly Note 1 Lift up the clip tab using a flathead screwdriver 2 Remove the clip pushing with a flathead screwdriver and a hammer as shown in...

Page 594: ...ssembly Note 1 Place the vanes in the rotor with the rounded edges contacting the cam Cam Ring Assembly Note 1 Install the cam ring in the front pump body with the mark facing upward Rear Pump Body As...

Page 595: ...TION P 31 TCS DSC OFF SWITCH INSPECTION P 32 FRONT ABS WHEEL SPEED SENSOR REMOVAL INSTALLATION P 32 FRONT REAR ABS WHEEL SPEED SENSOR INSPECTION P 33 REAR ABS WHEEL SPEED SENSOR REMOVAL INSTALLATION P...

Page 596: ...SECONDS WITH IGNITION SWITCH ON P 114 NO 9 TCS OFF LIGHT STAYS ON MORE THAN 4 SECONDS WITH IGNITION SWITCH ON P 116 NO 10 TCS DOES NOT WORK CORRECTLY P 117 NO 11 THERE IS MALFUNCTION IN THE SYSTEM EV...

Page 597: ...CYLINDER DISASSEMBLY ASSEMBLY 3 Power brake unit SeeP 14 POWER BRAKE UNIT INSPECTION SeeP 14 POWER BRAKE UNIT REMOVAL INSTALLATION 4 Dual proportioning valve without ABS SeeP 16 DUAL PROPORTIONING VAL...

Page 598: ...TYPE ADJUSTMENT SeeP 26 2 PARKING BRAKE LEVER TYPE REMOVAL INSTALLATION A6E6900W003 1 ABS ABS TCS HU CM SeeP 27 ABS ABS TCS HU CM SYSTEM INSPECTION SeeP 29 ABS ABS TCS HU CM INSPECTION SeeP 28 ABS AB...

Page 599: ...ON 2 Combine sensor SeeP 42 COMBINE SENSOR REMOVAL INSTALLATION SeeP 43 COMBINE SENSOR INSPECTION SeeP 44 COMBINE SENSOR INITIALIZATION PROCEDURE 3 Steering angle sensor SeeP 44 STEERING ANGLE SENSOR...

Page 600: ...TCS or DSC Components Operations 1 Make sure that there are no DTCs in the ABS ABS TCS or DSC memory after working on ABS ABS TCS or DSC components If there are any DTCs in the memory clear them End...

Page 601: ...ver in the direction of the arrow shown in the figure push the ring down and remove the vacuum hose 3 Apply both suction and pressure to the engine side hose and verify that air blows only toward that...

Page 602: ...rake Pedal Play Adjustment 1 Remove the spring pin and clevis pin See P 9 BRAKE PEDAL REMOVAL INSTALLATION 2 Loosen locknut D and turn rod C to align the holes in the fork and in the pedal 3 Install t...

Page 603: ...ed again Therefore replace the switch with a new one when replacing the power brake unit or the pedal or performing any procedure that changes the pedal stroke 1 For ATX model remove the lock unit wit...

Page 604: ...6E691243400W01 1 Remove in the order indicated in the table R H D L H D 2 Install in the reverse order of removal A6E6912W028 A6E6912W018 1 Brake fluid level sensor connector 2 Brake pipe 3 Hose MTX 4...

Page 605: ...gf cm 87 141 in lbf 2 Using a vacuum gauge create a vacuum pressure of 66 7 kPa 500 mmHg 19 7 inHg in the power brake unit 3 Using calipers measure dimension L as shown Specification 22 7 mm 8 94 in 4...

Page 606: ...d reinstall properly End Of Sie FLUID LEVEL SENSOR INSPECTION A6E691243540W01 1 Disconnect the negative battery cable 2 Disconnect the sensor connector 3 Inspect for continuity between terminals of fl...

Page 607: ...ton with the piston hole facing the stop pin and primary piston 2 Install the new O ring onto the stop pin 3 Push the primary piston assembly in full 4 Install and tighten the stop pin Tightening torq...

Page 608: ...e following inspection methods are the simple inspection methods to judge the function of power brake If there is malfunction in power brake unit replace the power brake unit as a component Power Brak...

Page 609: ...dal with a force of 196 N 20 kgf 44 lbf 3 Stop the engine when the vacuum gauge reading reaches 66 7 kPa 500 mmHg 19 7 inHg 4 Observe the vacuum gauge for 15 seconds 5 If the gauge shows 63 3 66 7 kPa...

Page 610: ...within the specification replace the dual proportioning valve Fluid pressure kPa kgf cm2 psi End Of Sie DUAL PROPORTIONING VALVE REPLACEMENT WITHOUT ABS A6E691243900W02 1 Remove in the order indicate...

Page 611: ...nsmitted to the brake pedal 2 The following are the main possible causes of brake judder Due to an excessive runout side to side wobble of disc plate the thickness of disc plate is uneven 1 If the run...

Page 612: ...ameter more than 12 mm 0 47 in between the hub bolt and the hub nut Note The component parts of the SST 49 B017 001 or 49 G019 003 can be used as a suitable washer 2 After tightening all the hub nuts...

Page 613: ...en machined Machine the disc plate while installed on the vehicle 1 Measure the thickness of the disc plate If the thickness is not within the specification replace the disc plate Minimum L8 LF GCC sp...

Page 614: ...te and wheel hub 2 Install the disc plate and align the marks made before removal A6E6912W301 9 8 7 5 5 4 3 1 2 6 6 SST SST R RUBBER GREASE 21 6 29 4 2 21 3 00 16 0 21 6 78 4 101 9 8 00 10 3 57 9 75 1...

Page 615: ...everse order of removal 49 0221 600C A6E6912W038 7 7 5 5 4 3 1 2 6 SST 6 SST GREASE 18 5 25 5 1 89 2 60 13 7 18 8 L8 LF GCC SPECS LF EUROPEAN L H D U K SPECS L3 L8 LF GCC SPECS 44 1 49 0 4 47 4 99 32...

Page 616: ...n from suddenly popping out 1 Place a piece of wood in the caliper then blow compressed air through the hole to force the piston out of the caliper Piston Seal Disassembly Note 1 Remove the piston sea...

Page 617: ...d Machine the disc plate while installed on the vehicle 1 Measure the thickness of the disc plate If the thickness is not within the specification replace the disc plate Minimum 8 mm 0 31 in Minimum t...

Page 618: ...s not drag A6A6912W008 9 7 7 5 4 3 1 2 10 6 8 8 6 SST SST R 51 0 66 7 5 21 6 80 37 7 49 1 21 6 29 4 2 21 2 99 16 0 21 6 37 3 49 0 3 81 4 99 27 6 36 1 N m kgf m ft lbf 9 8 14 7 N m 100 149 kgf cm 87 13...

Page 619: ...691226630W01 1 Remove in the order indicated in the table 2 Install in the reverse order of removal End Of Sie 49 FA18 602 A6E6912W039 A6A6912W009 N m kgf m ft lbf 37 3 49 0 3 81 4 99 27 6 36 1 2 3 4...

Page 620: ...15 14 13 11 12 5 9 8 8 61 89 53 77 37 3 49 0 N m 3 81 4 99 kgf m 27 6 36 1 ft lbf N m kgf cm in lbf BRAKE BRAKE FLUID FLUID SST GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE RU...

Page 621: ...the rear ashtray case in the direction shown by the arrow and remove clips A from the console 4 Disengage the hooks from the console and remove the rear ashtray case 5 Verify the position of the adju...

Page 622: ...ar seat 5HB See S 110 REAR SEAT REMOVAL INSTALLATION 3 Remove the exhaust pipe bracket 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 Adjust the parking brake...

Page 623: ...4 Send the command while pressing on the brake pedal and attempting to rotate the wheel being inspected 5 When pressure is being maintained and click sound indicating the solenoid is operating comes f...

Page 624: ...CM Replace it if it is subjected to an impact 1 Configurate the ABS ABS TCS HU CM when only replacing it See P 29 ABS ABS TCS or DSC HU CM CONFIGURATION 2 Remove the battery battery tray and battery...

Page 625: ...nect the WDS or equivalent to the DLC 2 2 Input vehicle information following the direction on the WDS or equivalent screen 3 Select Module programming 4 Select Programmable module installation 5 Sele...

Page 626: ...Reference I E LF wheel speed LF wheel speed sensor Vehicle is stopped 0 AC Inspect by using the wave profile See P 31 Inspection Using An Oscilloscope Reference H K L M N O CAN H No need to check P 1...

Page 627: ...iving 30 km h 18 6 mph Note As vehicle speed increases period of wave shortens End Of Sie TCS DSC OFF SWITCH REMOVAL INSTALLATION A6E692167650W02 1 Press the hooks of the TCS OFF switch and pull the s...

Page 628: ...using an ohmmeter If not within the specification replace the TCS OFF switch End Of Sie FRONT ABS WHEEL SPEED SENSOR REMOVAL INSTALLATION A6E692143720W01 1 Remove the mud guard 2 Remove in the order i...

Page 629: ...ace the ABS wheel speed sensor Resistance 1 3 1 7 kilohm Voltage Inspection 1 On level ground jack up the vehicle and support it evenly on safety stands 2 Disconnect the ABS wheel speed sensor connect...

Page 630: ...LLATION A6E692143710W01 1 Remove the tire house trim S 91 TIRE HOUSE TRIM REMOVAL INSTALLATION 2 Remove in the order indicated in the table 3 Install in the reverse order of removal End Of Sie A6E6916...

Page 631: ...inspect for brake drag Operation of DSC Inspection 1 Perform the Preparation 2 Connect WDS or equivalent to the DLC 2 3 Set up an active command modes inspection according to the combination of comma...

Page 632: ...inspections above determines the following The DSC HU CM brake lines are normal The DSC HU CM hydraulic system is not significantly abnormal The DSC HU CM wiring is normal Output system harness in DSC...

Page 633: ...are normal The DSC HU CM hydraulic system is not significantly abnormal The DSC HU CM wiring is normal Output system harness in DSC HU CM solenoid relay are normal However the following items cannot...

Page 634: ...to an impact 1 Configurate the DSC HU CM when only replacing it See P 29 ABS ABS TCS or DSC HU CM CONFIGURATION 2 Remove the battery battery tray and battery tray bracket See G 3 BATTERY REMOVAL INSTA...

Page 635: ...etely returned 3 Remove the harness side connector to the direction D DSC HU CM and Bracket Removal Installation Note 1 When removing installing the DSC HU CM from to the vehicle attach a strip of tap...

Page 636: ...ed sensor Vehicle is stopped 0 AC Inspect related harness Inspect wheel speed sensor Inspect using the wave profile See P 41 Inspection Using An Oscilloscope Reference M I RF wheel speed RF wheel spee...

Page 637: ...Reference Inspect related harness Inspect steering angle sensor X Steering angle steering angle signal 1 Steering angle sensor Inspect using the wave profile See P 41 Inspection Using An Oscilloscope...

Page 638: ...cle condition Driving 30 km h 18 6 mph Note As vehicle speed increases period of wave shortens End Of Sie COMBINE SENSOR REMOVAL INSTALLATION A6E692067650W05 Caution Be careful and do not allow the co...

Page 639: ...nition switch on verify the voltage between terminals B and E under the following conditions If not within the specification replace the lateral G sensor 1 Lateral G 1 Horizontal Voltage 2 4 2 6 V 2 F...

Page 640: ...t the SST WDS or equivalent to the DLC 2 2 Access the active command mode and select the YAWRATE then follow the indication on the monitor 3 Select the LATACCEL and follow the indication on the monito...

Page 641: ...fuse 3 ABS 60 A fuse 4 Meter 5 ABS warning light 6 Brake system warning light 7 TCS OFF light 8 TCS indicator light 9 CAN driver 10 Brake light 11 Cruise actuator 12 TCS OFF switch 13 DLC 2 14 CAN H...

Page 642: ...tic results This function allows you to read or clear DTCs in the ABS ABS TCS HU CM memory PID data monitor and record This function allows you to access certain data values input signals calculated v...

Page 643: ...ed sensor See P 56 DTC C1145 C1155 C1165 C1175 C1168 Right rear wheel speed sensor sensor rotor See P 59 DTC C1148 C1158 C1168 C1178 C1233 C1234 C1235 C1236 C1175 Left rear wheel speed sensor See P 56...

Page 644: ...44 DTC U0073 U1900 U2516 PID Name Definition Unit Condition Condition Specification Action ABS ABS TCS HU CM CM terminal RPM Engine speed signal input RPM Engine is stopped 0 RPM Engine is running Ind...

Page 645: ...tion solenoid valve output state ON OFF During ABS or EBD control ON OFF solenoid valve is activated deactivated Not ABS and EBD control OFF solenoid valve is deactivated Internal fault of ABS ABS TCS...

Page 646: ...ail safe relay ON OFF Ignition key at ON Engine OFF and driving LR_OUTLET Left rear ABS pressure reduction solenoid valve ON OFF LR_INLET Left rear ABS pressure retention solenoid valve ON OFF RR_INLE...

Page 647: ...terminal Z and ground Is voltage above 10 V Yes Go to next step No Go to Step 6 5 INSPECT ABS ABS TCS HU CM GROUND CIRCUIT FOR POOR GROUND OR OPEN CIRCUIT Turn ignition key to OFF Measure resistance...

Page 648: ...ne and drive vehicle at 10 km h 6 2 mph or above Is same DTC present Yes Replace ABS ABS TCS HU CM then go to next step No Inspect intermittent concern using the same procedure as engine control syste...

Page 649: ...dapter harness to ABS ABS TCS HU CM connector harness side only Turn ignition key to ON engine OFF Measure voltage between ABS ABS TCS HU CM terminal AB harness side of SST and ground Is voltage B Yes...

Page 650: ...TING COMPLETED Clear DTC from memory See P 46 Clearing DTCs Procedures Start engine and drive vehicle at 10 km h 6 2 mph or above Gradually slow down and stop vehicle Is same DTC present Yes Replace A...

Page 651: ...ront and left rear wheels or left front and right rear wheel lock is detected during ABS ABS TCS operation POSSIBLE CAUSE Stuck pump motor in ABS ABS TCS HU CM STEP INSPECTION ACTION 1 INSPECT ABS ABS...

Page 652: ...in harness between ABS ABS TCS HU CM terminal and wheel speed sensor s terminal below ABS ABS TCS HU CM terminal G RF ABS wheel speed sensor terminal A ABS ABS TCS HU CM terminal D RF ABS wheel speed...

Page 653: ...ON BOARD DIAGNOSTIC ABS TCS P 57 P...

Page 654: ...or s and inspect resistance between sensor terminals part side Is resistance within 1 3 1 7 kilohm Yes Go to next step No Replace wheel speed sensor then go to Step 5 4 INSPECT ABS ABS TCS HU CM TO WH...

Page 655: ...vehicle goes from start to a speed of 10 km h 6 2 mph Greater than specified amount of ABS demand occurs from front wheel sensors when vehicle is started C1234 C1233 C1235 C1236 Abnormal sensor outpu...

Page 656: ...ABS TCS Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY OTHER DTC HAS BEEN RECORDED Have DTCs related to solenoid valve pump motor or pump motor relay been stored Yes Go to applicable DTC inspec...

Page 657: ...G ground LF wheel speed sensor I ground RR wheel speed sensor A ground LR wheel speed sensor C ground Is there continuity Yes Repair or replace harness for short to ground circuit between ABS ABS TCS...

Page 658: ...h 6 2 mph or above Gradually slow down vehicle and stop Is same DTC present Yes Replace ABS ABS TCS HU CM then go to next step No Go to next step 10 VERIFY AFTER REPAIR PROCEDURE Is there any other DT...

Page 659: ...VERIFY AFTER REPAIR PROCEDURE Is there any other DTC present Yes Go to applicable DTC inspection No Troubleshooting completed DTC C 1210 C 1214 C 1194 C 1198 C 1246 C 1254 C 1242 C 1250 RF pressure re...

Page 660: ...Go to applicable DTC inspection No Troubleshooting completed DTC C1508 TCS control DETECTION CONDITION TCS control continues operation for 60 seconds or more POSSIBLE CAUSE System is normal For prote...

Page 661: ...4 VERIFY AFTER REPAIR PROCEDURE Is there any other DTC present Yes Go to applicable DTC inspection No Troubleshooting completed DTC U2021 Engine coolant temperature DETECTION CONDITION After engine is...

Page 662: ...DYNAMIC STABILITY CONTROL DSC SYSTEM WIRING DIAGRAM A6E697367650W01 ON BOARD DIAGNOSTIC DYNAMIC STABILITY CONTROL A6E6920T005 1 IG switch 2 SUS 15A fuse 3 ABS 60 A fuse 4 Meter 5 ABS warning light 6 B...

Page 663: ...ed sensor See P 81 DTC C1145 C1155 C1165 C1175 C1148 Right front wheel speed sensor sensor rotor See P 83 DTC C1148 C1158 C1168 C1178 C1233 C1234 C1235 C1236 C1155 Left front wheel speed sensor See P...

Page 664: ...400 C1410 C1957 C1958 C1414 DSC HU CM See P 91 DTC C1414 C1507 DSC control See P 91 DTC C1507 C1508 C1508 DSC control See P 91 DTC C1507 C1508 C1510 Right front solenoid valve motor or wheel speed sen...

Page 665: ...is deactivated OFF Internal fault of DSC HU CM Replace DSC HU CM See P 38 DSC HU CM REMOVAL INSTALLATION L_DSC O Stability control solenoid valve LF RR ON OFF Solenoid valve is activated ON Solenoid v...

Page 666: ...alve is activated deactivated Not ABS control OFF solenoid valve is deactivated Internal fault of DSC HU CM Replace DSC HU CM See P 38 DSC HU CM REMOVAL INSTALLATION ABSRR_I Right rear ABS pressure re...

Page 667: ...Indicates vehicle speed Inspect wheel speed sensor sensor rotor H K LAT ACC Lateral G sensor input G Vehicle is stopped or driving straight 0 G Cornering to left Changes between 0 G and 1 27 G Corneri...

Page 668: ...lenoid valve ON OFF LF_OUTLET Left front ABS pressure reduction solenoid valve ON OFF RF_INLET Right front ABS pressure retention solenoid valve ON OFF RF_OUTLET Right front ABS pressure reduction sol...

Page 669: ...ween DSC HU CM terminal G and ground Is voltage above 10 V Yes Go to next step No Go to Step 6 5 INSPECT DSC HU CM GROUND CIRCUIT FOR POOR GROUND OR OPEN CIRCUIT Turn ignition key to OFF Measure resis...

Page 670: ...ring DTCs Procedures Start engine and drive vehicle at 10 km h 6 2 mph or above Is same DTC present Yes Replace DSC HU CM then go to next step No Inspect intermittent concern using the same procedure...

Page 671: ...Turn ignition key to OFF Inspect continuity DSC HU CM terminal L and ground Is there continuity Yes Repair or replace harness for open circuit between DSC HU CM and brake switch then go to next step N...

Page 672: ...the SST 49 G066 004 must be used DTC B1627 Reverse signal DETECTION CONDITION Reverse signal is input for 10 seconds or more while driving at a vehicle speed of 65 km h 40 3 mph POSSIBLE CAUSE Short...

Page 673: ...ther DTC present Yes Go to applicable DTC inspection No Troubleshooting completed DTC B2477 Module configuration DETECTION CONDITION Configuration write failure is detected POSSIBLE CAUSE Module confi...

Page 674: ...CM connector Connect SST adapter harness to DSC HU CM connector harness side only Turn ignition key to ON engine OFF Measure voltage between DSC HU CM terminal D harness side of SST and ground Is volt...

Page 675: ...HOOTING COMPLETED Clear DTC from memory See P 46 Clearing DTCs Procedures Start engine and drive vehicle at 10 km h 6 2 mph or above Gradually slow down and stop vehicle Is same DTC present Yes Replac...

Page 676: ...re POSSIBLE CAUSE Decrease in amount of brake fluid Malfunction of brake fluid level sensor STEP INSPECTION ACTION 1 CHECK FOR CAN FOR DTCs Is any of DTC U1900 and or U2516 has also been stored Yes Fo...

Page 677: ...s rear brake dragging Yes Repair parking brake system then go to next step No Go to next step 4 VERIFY TROUBLESHOOTING COMPLETED Clear DTC from memory See P 46 Clearing DTCs Procedures Start engine an...

Page 678: ...OPEN CIRCUIT Turn ignition key to OFF Disconnect DSC HU CM connector Measure resistance between suspected sensor terminals of DSC HU CM connector harness side RF wheel speed sensor M I LF wheel speed...

Page 679: ...M connector and or wheel speed sensor connector s then go to next step No Repair or replace harness for open circuits between DSC HU CM and wheel speed sensor s then go to next step 5 VERIFY TROUBLESH...

Page 680: ...STABILITY CONTROL Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY OTHER DTC HAS BEEN RECORDED Have DTCs related to solenoid valve pump motor or pump motor relay been stored Yes Go to applicable D...

Page 681: ...sensor M ground LF wheel speed sensor F ground RR wheel speed sensor K ground LR wheel speed sensor Q ground Is there continuity Yes Repair or replace harness for short to ground circuit between DSC...

Page 682: ...above Gradually slow down vehicle and stop Is same DTC present Yes Replace DSC HU CM then go to next step No Go to next step 10 VERIFY AFTER REPAIR PROCEDURE Is there any other DTC present Yes Go to a...

Page 683: ...Y TROUBLESHOOTING COMPLETED Clear DTC from memory See P 46 Clearing DTCs Procedures Is same DTC present Yes Replace DSC HU CM then go to next step No Go to next step 6 VERIFY AFTER REPAIR PROCEDURE Is...

Page 684: ...RIFY TROUBLESHOOTING COMPLETED Clear DTC from memory See P 46 Clearing DTCs Procedures Start engine and drive vehicle at 10 km h 6 2 mph or above Gradually slow down and stop vehicle Is same DTC prese...

Page 685: ...re within 1 cycle is detected 8 times in 1 second C1959 Lateral G sensor part 0 point correction value is 3 or more or 2 or less Output voltage value from lateral G sensor part remains absolutely unch...

Page 686: ...UND Turn ignition key to OFF Inspect continuity between DSC HU CM terminal T harness side and ground Is there continuity Yes Repair or replace harness for short to ground circuit between DSC HU CM ter...

Page 687: ...es Go to next step No Replace DSC HU CM 4 VERIFY TROUBLESHOOTING COMPLETED Make sure to reconnected all disconnect connectors Clear DTC from memory See P 46 Clearing DTCs Procedures Is same DTC presen...

Page 688: ...vehicle at 10 km h 6 2 mph or above at least one minute Gradually slow down and stop vehicle Is same DTC present Yes Replace DSC HU CM then go to next step No Go to next step 4 VERIFY AFTER REPAIR PRO...

Page 689: ...urned in specified direction neutral position is detected even when rotated at 18 degrees or more j POSSIBLE CAUSE Open circuit in harness between steering angle sensor terminal A and ignition switch...

Page 690: ...e harness for open circuit between steering angle sensor terminal A and ignition switch then go to Step 7 2 INSPECT STEERING ANGLE SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT Turn ignition key to OFF Disco...

Page 691: ...to power circuit between DSC HU CM terminal and steering angle sensor terminal then go to Step 7 No Go to next step 5 INSPECT STEERING ANGLE SENSOR SIGNAL CIRCUIT FOR SHORT TO GROUND Turn ignition key...

Page 692: ...HER ENGINE HAS WARMED UP Has engine warmed up Yes Go to next step No Warm up the engine If DSC OFF light goes out system is normal 2 VERIFY THAT MALFUNCTION SYMPTOM OCCURS AFTER ENGINE IS WARMED UP Wa...

Page 693: ...1 IG switch 2 SUS 15 A fuse 3 ABS 60 A fuse 4 Meter 5 ABS warning light 6 Brake system warning light 7 TCS OFF light 8 TCS indicator light 9 CAN driver 10 Brake light 11 Cruise actuator 12 TCS OFF swi...

Page 694: ...C STABILITY CONTROL DSC A6E6920T005 1 IG switch 2 SUS 15A fuse 3 ABS 60 A fuse 4 Meter 5 ABS warning light 6 Brake system warning light 7 DSC OFF light 8 DSC indicator light 9 CAN driver 10 Battery 11...

Page 695: ...ght will go out ABS EBD TCS and DSC control Any or all the following light s illuminate ABS warning light BRAKE system warning light 1 Under any of the following conditions When the front wheels are j...

Page 696: ...10km h 6 2mph make sure that ABS warning light goes off and then clear the DTC The BRAKE system warning light also illuminates when any rear wheel malformations When repairing if the ABS TCS related...

Page 697: ...sure the ABS warning light goes off and then clear the DTC When repairing if the DSC related connectors are disconnected and the ignition switch is turned on the control module will mistakenly detect...

Page 698: ...uld cause an electrical malfunction Check the following Connectors not fully seated Wire harnesses not having full play Wires laying across brackets or moving parts Wires routed too close to hot parts...

Page 699: ...ith your finger If PID value is unstable or malfunction occurs check for poor connection and or poorly mounted sensor Malfunction data monitor method 1 Perform malfunction reappearance test according...

Page 700: ...onds with ignition with on 7 ABS warning light stays on more than 4 seconds with ingestion switch on 8 BRAKE system warning light stays on more than 4 seconds with ignition switch on Parking brake is...

Page 701: ...TROUBLESHOOTING ABS TCS DYNAMIC STABILITY CONTROL P 105 P Vehicle with ABS TCS A6E6980W002...

Page 702: ...P 106 TROUBLESHOOTING ABS TCS DYNAMIC STABILITY CONTROL Vehicle with DSC End Of Sie A6E6980W100...

Page 703: ...CT INSTRUMENT CLUSTER POWER SUPPLY FUSE Is instrument cluster ignition power supply fuse okay Yes Go to next step No Check for a short to ground on blown fuse s circuit Repair or replace as necessary...

Page 704: ...R POWER SUPPLY FUSE Is instrument cluster ignition power supply fuse okay Yes Go to next step No Check for a short to ground on blown fuse s circuit Repair or replace as necessary Install appropriate...

Page 705: ...VALENT ABS_MSG PCM_MSG Is not present massage displayed on WDS or equivalent Yes Replace instrument cluster open circuit in instrument cluster No Network communication for related system is malfunctio...

Page 706: ...etrieved Yes Go to next step No Inspect instrment cluster If OK then go to step6 4 COMFIRM THE FOLLOWING PIDs USING WDS OR EQUIVALENT ABS_MSG PCM_MSG Is not present massage displayed on WDS or equival...

Page 707: ...tion ABS TCS HU CM detects low voltage in power supply ABS TCS CM ingestion terminal Z voltage is below about 9 to 10 V ABS TCS HU CM does not operate Malfunction of communication network STEP INSPECT...

Page 708: ...12 V at SST connector terminal Z Yes Go to next step No Check for connection of ABS TCS HU CM connector securely 9 INSPECT WIRING HARNESS BETWEEN ABS TCS HU CM GROUND FOR CONTINUITY Turn ignition swit...

Page 709: ...Cs been recorded in memory Yes Perform inspection using appropriate DTC No Go to next step 3 INSPECT PID DATA IN ABS TCS HU CM Inspect the following items using WDS or equivalent PID DATA monitor func...

Page 710: ...CS HU CM STEP INSPECTION ACTION 8 BRAKE system warning light stays on more than 4 seconds with ignition switch on Parking brake is released TROUBLESHOOTING HINTS Malfunction of instrment cluster or AB...

Page 711: ...art No Perform the following inspections Repair if necessary Short to ground in wiring harness between instrument cluster BRAKE system warning light and parking brake switch Short to ground in wiring...

Page 712: ...ng items using WDS or equivalent PID DATA monitor function TRAC_SW TCS OFF switch Is TRAC_SW ON displayed on WDS or equivalent Yes Go to Step 5 TCS OFF switch system malfunction No Go to next step 4 C...

Page 713: ...torque reduction signal using WDS or equivalent Increase the engine speed to 3 000 rpm Input 280 N m ENG _ TRQ to PCM using WDS or equivalent Does engine speed decrease Yes System is normal Recheck c...

Page 714: ...AKE SYSTEM WARNING LIGHT If DSC indicator light and TCS OFF light do not illuminate go to Step 6 If ABS warning light and BRAKE system warning light do not illuminate go to Step 8 6 CHECK TO SEE WHETH...

Page 715: ...o next step 3 CHECK TO SEE WHETHER MALFUNCTION IS IN CONTROL MODULE CONNECTOR TERMINAL OR OTHER Do ABS warning light and BRAKE system warning light go off after 4 seconds with ignition switch on Yes T...

Page 716: ...1 DSC system function contains traction control function DSC indicator light goes on and off while DSC operates TROUBLESHOOTING HINTS There is difference in size or air pressure between the front and...

Page 717: ...tion is not performed correctly DSC may not work correctly STEP INSPECTION ACTION 1 CHECK DSC HU CM FOR DTCs Check the DTC for the DSC ON BOARD DIAGNOSTIC SYSTEM Have DTCs been recorded in memory Yes...

Page 718: ...L INSTALLATION R 15 FRONT LOWER ARM FRONT INSPECTION R 18 FRONT LOWER ARM REAR REMOVAL INSTALLATION R 19 FRONT LOWER ARM REAR INSPECTION R 21 FRONT STABILIZER REMOVAL INSTALLATION R 22 STABILIZER CONT...

Page 719: ...L INSTALLATION See R 14 FRONT UPPER ARM INSPECTION 4 Front lower arm front See R 15 FRONT LOWER ARM FRONT REMOVAL INSTALLATION See R 18 FRONT LOWER ARM FRONT INSPECTION 5 Front lower arm rear See R 19...

Page 720: ...L SPRING REMOVAL INSTALLATION 3 Rear upper arm SeeR 31 REAR UPPER ARM REMOVAL INSTALLATION 4 Rear lower arm SeeR 30 REAR LOWER ARM REMOVAL INSTALLATION 5 Rear lateral link SeeR 33 REAR LATERAL LINK RE...

Page 721: ...inspect for leakage after the procedure has been completed Power Steering Components Removal Installation 1 If any power steering fluid line has been disconnected anytime during the procedure add ATF...

Page 722: ...cknuts and turn the tie rods equally Both tie rods are right threaded so turning the right tie rod toward the front of the vehicle and the left toward the rear increases toe in Note Turning both tie r...

Page 723: ...s indicated 3 Tighten the cam nut Tightening torque 86 2 116 6 N m 8 79 11 88 kgf m 63 58 85 99 ft lbf Total Toe in Adjustment 1 Loosen the locknut of the lateral link Item Fuel gauge indication Empty...

Page 724: ...alancer measure the amount of unbalance and the position with the mode set for knock type balance weight 4 Multiply the amount of unbalance by 1 6 to get the balance weight value 5 Select a balance we...

Page 725: ...ights must not exceed 100g 3 53 oz Remaining Amount of Unbalance Confirmation 1 After installing the outer and inner balance weights operate the wheel balancer again 2 Confirm that the remaining unbal...

Page 726: ...indicated in the table 2 Install in the reverse order of removal FRONT SUSPENSION A6E7414W017 1 Bolt ABS wheel speed sensor 2 Bolt brake hose bracket 3 Nut front stabilizer control link 4 Bolt front s...

Page 727: ...t the coil spring using a piece of cloth then set the SSTs 2 Compress the coil spring using the SSTs and remove the piston rod nut Coil Spring Installation Note 1 Temporarily install the coil spring d...

Page 728: ...e shock absorber and dust boot are aligned 7 Install the mounting rubber and piston rod nut then remove the SSTs Piston rod nut tightening torque 39 2 52 9 N m 4 00 5 39 kgf m 29 0 39 0 ft lbf Front S...

Page 729: ...y that the piston extends fully at a normal speed End Of Sie FRONT SHOCK ABSORBER DISPOSAL A6E741434700W02 Warning Whenever drilling into a shock absorber wear protective eye wear The gas in the shock...

Page 730: ...d by mistake while servicing the vehicle 1 Remove in the order indicated in the table 2 Install in the reverse order of removal 3 Inspect the front wheel alignment See R 5 FRONT WHEEL ALIGNMENT Front...

Page 731: ...e 3 Install the boot on the ball joint 4 Install the new clip using the SST 5 Verify that the clip is installed securely to the groove 6 Wipe away the excess grease End Of Sie FRONT UPPER ARM INSPECTI...

Page 732: ...bsorber lower side 3 Dynamic damper 4 Bolt front lower arm inner side 5 Front lower arm front component 6 Clip See R 18 Clip Installation Note 7 Dust boot 8 Front lower arm front bushing inner side Se...

Page 733: ...ront Bushing Inner Side Removal Note 1 Press the bushing inner side out using the SSTs Front Lower Arm Front Bushing Outer Side Removal Note 1 Press the bushing outer side out using the SSTs Front Low...

Page 734: ...erify that clearance distance A B is 8 75 mm 10 75 mm 0 3445 in 0 4232 in Front Lower Arm Front Bushing Inner Side Installation Note 1 Mark the new bushing as shown in the figure 2 Press the bushing i...

Page 735: ...ely to the groove 6 Wipe away the excess grease End Of Sie FRONT LOWER ARM FRONT INSPECTION A6E741434300W03 1 Remove the lower arm front from the vehicle 2 Inspect for damage cracks and bending 3 Insp...

Page 736: ...arate the ball joint from the knuckle using the SSTs B6U0213W013 8 7 5 4 3 1 2 6 166 6 200 0 16 99 20 39 122 9 147 5 43 1 54 9 4 40 5 59 21 8 40 4 93 1 126 4 9 50 12 88 68 67 93 22 119 6 154 8 12 20 1...

Page 737: ...Note 1 Support the front crossmember with a jack 2 Loosen the front crossmember installation bolts front side 3 Remove the front crossmember installation bolts rear side 4 Remove the front lower arm r...

Page 738: ...ront Lower Arm Rear Installation Note 1 Install the lower arm rear so that identification mark L or R faces toward the front of the vehicle End Of Sie FRONT LOWER ARM REAR INSPECTION A6E741434300W04 1...

Page 739: ...31 HEADLIGHT ZEROSET 5 Inspect the front wheel alignment See R 5 FRONT WHEEL ALIGNMENT Stabilizer Bracket Installation Note 1 Apply rubber grease to the inside surface of the stabilizer bushing 2 Alig...

Page 740: ...e splash shield 3 Remove the front auto leveling sensor See T 32 FRONT AUTO LEVELING SENSOR REMOVAL INSTALLATION 4 Remove the transverse member See R 27 TRANSVERSE MEMBER REMOVAL INSTALLATION 5 Remove...

Page 741: ...nt shock absorber lower side 5 No 1 engine mount center bolt See R 25 No 1 Engine Mount Center Bolt Removal Note 6 Crossmember bracket See R 25 Crossmember Bracket Removal Note 7 Crossmember component...

Page 742: ...serious injury or death Verify that the jack securely supports the crossmember component before removing the crossmember bracket 1 Support the crossmember component with a jack and remove the nuts 2 R...

Page 743: ...R 26 FRONT SUSPENSION Front Crossmember Bushing Installation Note 1 Set the bushings as shown in the figure 2 Install the bushing onto the crossmember using the SSTs End Of Sie A6E7414W041 A6E7414W042...

Page 744: ...nstall in the reverse order of removal Transverse Cover Installation Note 1 Install the transverse cover 2 Stake area A as shown in the figure End Of Sie 1 Transverse member and transverse cover 2 Tra...

Page 745: ...e in the order indicated in the table 2 Install in the reverse order of removal Bracket Installation Note 1 Install the bracket as shown in the figure End Of Sie REAR SHOCK ABSORBER INSPECTION A6E7416...

Page 746: ...REAR WHEEL ALIGNMENT Bolt Rear Lower Arm Outer Side Removal Note 1 Support the lower arm with a jack 2 Loosen the inner bolt of the lower arm 3 Remove the outer bolt of the lower arm A6E7416W022 1 Bo...

Page 747: ...rning Installing the coil spring is dangerous The coil spring could fly off and cause serious injure of death 3 Install the lower arm outer side bolt End Of Sie REAR LOWER ARM REMOVAL INSTALLATION A6E...

Page 748: ...ot be pulled by mistake while servicing the vehicle 1 Remove in the order indicated in the table 2 Install in the reverse order of removal 3 Inspect the rear wheel alignment See R 6 REAR WHEEL ALIGNME...

Page 749: ...e 1 Loosen the bolts on the inner and outer side of the lateral link Rear Upper Arm Bushing Removal Note 1 Press the upper arm bushing out using the SSTs Rear Upper Arm Bushing Installation Note 1 Mar...

Page 750: ...ear suspension avoid any impact to the fuel tank 2 Measure the length L shown in the figure for proper installation 3 Temporarily loosen a locknut of the rear lateral link 4 Install the rear lateral l...

Page 751: ...eling sensor See T 32 REAR AUTO LEVELING SENSOR REMOVAL INSTALLATION 2 Remove in the order indicated in the table 3 Install in the reverse order of removal 4 Adjust the headlight zeroset See T 31 HEAD...

Page 752: ...W01 Caution Performing the following procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake Before performing the fol...

Page 753: ...control link lower side 7 Bolt rear lower arm outer side See R 29 Bolt Rear Lower Arm Outer Side Removal Note 8 Spring component 9 Bolt rear shock absorber lower side 10 Bolt trailing link front side...

Page 754: ...side End Of Sie REAR CROSSMEMBER REMOVAL INSTALLATION A6E741628400W01 Caution Performing the following procedures without first removing the ABS wheel speed sensor may possibly cause an open circuit i...

Page 755: ...ng brake cable 3 Caliper component See R 39 Caliper Component Removal Note 4 Disc plate 5 Spindle and hub component See M 10 WHEEL HUB HUB SPINDLE REMOVAL INSTALLATION 6 Bolt stabilizer control link 7...

Page 756: ...rossmember component Rear Crossmember Bushing Removal Note 1 Remove the bushing using screw driver being care not to damage the rear crossmember 8 Rear lower arm See R 30 REAR LOWER ARM REMOVAL INSTAL...

Page 757: ...e bushings as shown in the figure 2 Tap the bushing onto the rear crossmember using the SSTs Bolt Trailing Link Front Side Installation Note 1 Support the trailing link with a jack 2 Tighten the bolts...

Page 758: ...TION S 29 POWER WINDOW MOTOR INSPECTION S 29 POWER DOOR LOCK SYSTEM S 30 FRONT DOOR LOCK ACTUATOR INSPECTION S 30 REAR DOOR LOCK ACTUATOR INSPECTION S 32 TRUNK LID LOCK ACTUATOR INSPECTION S 32 LIFTGA...

Page 759: ...ISASSEMBLY ASSEMBLY S 83 SIDE PANEL REMOVAL INSTALLATION S 83 COLUMN COVER REMOVAL INSTALLATION S 84 METER HOOD REMOVAL INSTALLATION S 84 LOWER PANEL REMOVAL INSTALLATION S 84 CENTER BOX REMOVAL INSTA...

Page 760: ...DOW SYSTEM S 120 INTERMITTENT CONCERN TROUBLESHOOTING S 120 FOREWORD S 120 BASIC POWER WINDOW SYSTEM INSPECTION S 121 TROUBLESHOOTING INDEX S 123 NO 1 DRIVER SIDE FRONT WINDOW DOES NOT GO UP AND DOWN...

Page 761: ...MOTOR INSPECTION See S 80 SUNROOF RELAY INSPECTION 9 Deflector See S 74 DEFLECTOR REMOVAL INSTALLATION 10 Glass panel See S 74 GLASS PANEL REMOVAL INSTALLATION See S 75 GLASS PANEL ADJUSTMENT 11 Sunr...

Page 762: ...TALLATION 10 Rear beltline molding See S 56 REAR BELTLINE MOLDING REMOVAL See S 56 REAR BELTLINE MOLDING INSTALLATION 11 Side protector See S 52 SIDE PROTECTOR REMOVAL See S 53 SIDE PROTECTOR INSTALLA...

Page 763: ...ANGE PROCEDURE 8 Front door trim See S 90 FRONT DOOR TRIM REMOVAL INSTALLATION 9 Front scuff plate See S 89 FRONT SCUFF PLATE REMOVAL INSTALLATION 10 Lower panel See S 84 LOWER PANEL REMOVAL INSTALLAT...

Page 764: ...SUNROOF SWITCH INSPECTION 3 Sunvisor See S 98 SUNVISOR REMOVAL INSTALLATION 4 Shock absorbing pad See S 97 SHOCK ABSORBING PAD REMOVAL INSTALLATION 5 B pillar upper trim See S 88 B PILLAR UPPER TRIM R...

Page 765: ...L INSTALLATION See S 103 SEAT BELT INSPECTION 17 Tire house trim See S 91 TIRE HOUSE TRIM REMOVAL INSTALLATION 18 Rear scuff plate See S 89 REAR SCUFF PLATE REMOVAL INSTALLATION 19 Front floor coverin...

Page 766: ...FRONT DOOR LOCK ACTUATOR INSPECTION 8 Rear door latch and lock actuator See S 19 REAR DOOR LATCH AND LOCK ACTUATOR REMOVAL INSTALLATION See S 32 REAR DOOR LOCK ACTUATOR INSPECTION 9 Front outer handl...

Page 767: ...rection of the arrow using a tape wrapped small flathead screwdriver disengage it from the dashboard Caution Remove the bonnet release lever while taking care not to damage the bonnet release cable wi...

Page 768: ...08 0 17 in Height Adjustment 1 Turn the stop rubber to adjust the height of the bonnet 2 Verify that the height between the bonnet and the body is within the specification Clearance a 3 0 6 0 mm 0 12...

Page 769: ...molding See S 50 COWL GRILLE REMOVAL INSTALLATION 4 Remove the front bumper See S 47 FRONT BUMPER REMOVAL INSTALLATION 5 Remove the front combination light See T 26 FRONT COMBINATION LIGHT REMOVAL IN...

Page 770: ...Front door latch and lock actuator 5 Front door unit 6 Hole cover 7 Power window motor 8 Power window regulator 9 Inner handle 10 Protector 11 Outer handle 12 Front door key cylinder 13 Front door gl...

Page 771: ...ear door unit 6 Hole cover 7 Power window motor 8 Regulator handle 9 Power window regulator 10 Manual window regulator 11 Inner handle 12 Outer handle 13 Rear door glass 14 Quarter window glass 15 Gla...

Page 772: ...INSTALLATION A6E771472010W02 Warning Handling the side air bag sensor improperly can accidentally deploy the side air bag module which may seriously injure you Read AIR BAG SYSTEM SERVICE WARNINGS be...

Page 773: ...4 5 mm 0 10 0 18 in b 0 8 1 2 mm 0 03 0 05 in c 0 3 1 7 mm 0 01 0 07 in d 1 0 1 0 mm 0 04 0 04 in e 0 5 1 5 mm 0 02 0 06 in 3 Tighten the bolts or screws End Of Sie FRONT DOOR GLASS REMOVAL INSTALLATI...

Page 774: ...rear door trim 3 Remove the hole cover 4 Pull up the rear door weatherstrip and remove the screw 5 Remove the bolt 6 Remove the glass run channel from the rear door glass guide 7 Lift the rear door gl...

Page 775: ...ock knob cable from the hole 11 Remove the power window motor and power window regulator from the door unit 12 Install in the reverse order of removal End Of Sie REAR DOOR UNIT REMOVAL INSTALLATION A6...

Page 776: ...RONT DOOR LATCH AND LOCK ACTUATOR REMOVAL INSTALLATION A6E771458310W01 1 Remove the front door unit 2 Remove the screws then remove the front door latch and door lock actuator 3 Install in the reverse...

Page 777: ...vehicles pull out the protector tab from the latch and remove the protector 4 Disconnect the rod 5 Remove the front outer handle 6 Turn the key cylinder in the direction indicated by the arrow 1 and m...

Page 778: ...ide of the outer handle from the front door 7 Install in the reverse order of removal End Of Sie REAR OUTER HANDLE REMOVAL INSTALLATION A6E771458410W02 1 Remove the rear door glass 2 Remove the rear d...

Page 779: ...3 Pull off the inner handle and remove the door lock knob cable and inner handle cable 4 Install in the reverse order of removal End Of Sie REGULATOR HANDLE REMOVAL A6E771458580W01 1 Remove the regul...

Page 780: ...switch to the ON position 2 Press the driver side power window main switch and fully open the driver side window 3 Pull up the driver side power window main switch to manual up position to fully close...

Page 781: ...lowing procedure verify that the two step down function operates normally and the door glass position has changed If the two step down function does not operate or the door glass position has not chan...

Page 782: ...ITCH REMOVAL INSTALLATION A6E771666350W04 1 Disconnect the negative battery cable 2 Remove the front door trim or rear door trim 3 Remove the screws then the power window switch 4 Install in the rever...

Page 783: ...indow motor Inspect related harness While door glass is closing B 1F 1L 2 Door switch Door switch Any door is open door switch is on inspect for continuity to ground Yes Inspect door switch Inspect re...

Page 784: ...xcept driver s side 1 Turn the power cut switch to UNLOCK 2 Inspect for continuity between the power window main switch terminals using an ohmmeter If not as specified replace the power window main sw...

Page 785: ...ON A6E771658560W01 1 Disconnect the negative battery cable 2 Remove the front door glass rear door glass 3 Remove the front door speaker rear door speaker 4 Remove the power window motor 5 Remove the...

Page 786: ...he door speaker insert your hand in the speaker installation hole connect the drum housing hooks and while supporting the drum housing install the power window motor to the drum End Of Sie POWER WINDO...

Page 787: ...ont door lock actuator connector 2 Apply battery positive voltage to the front door lock actuator terminals and inspect the operation of the front door lock actuator If not as specified replace the fr...

Page 788: ...erminals using an ohmmeter If not as specified replace the front door lock actuator Door Key Cylinder Switch 1 Disconnect the front door lock actuator connector 2 Inspect for continuity between the do...

Page 789: ...Inspect for continuity between the door lock link switch terminals using an ohmmeter If not as specified replace the front door lock actuator End Of Sie TRUNK LID LOCK ACTUATOR INSPECTION A6E771856840...

Page 790: ...e the glove compartment L H D 3 Remove the bolt 4 While inclining the door lock timer unit along the body panel in the direction indicated by the arrow disengage the bracket hook from the hole in the...

Page 791: ...t Inspect courtesy light Inspect related harness 1C Unlock output Door lock actuator Trunk lid lock actuator 4SD Liftgate lock actuator 5HB While lock actuator is unlocking Below 1 0 B Below 1 0 Inspe...

Page 792: ...open any door switch is on Below 1 0 Inspect door switches Inspect related harness All door are closed door switches are off B 2L 2N 2M 2O 2P 2 Theft deterrent alarm control Theft deterrent control mo...

Page 793: ...erify that door lock actuators lock then unlock Push any button on any single transmitter twice Verify that door lock actuators lock then unlock If you have only one transmitter push any button twice...

Page 794: ...y A and remove the battery 3 Install a new battery CR2025 into the front portion of the holder with the positive pole facing up Press on the B portion of the battery to set the battery 4 Align the fro...

Page 795: ...t 30 minutes before reinspecting if a measurement value is under the standard voltage 1 Remove the transmitter cover 2 Apply the circuit tester leads to the positions as indicated in the figure 3 Whil...

Page 796: ...y damper 1 Disconnect the negative battery cable 2 Disconnect the trunk lid harness connector pull the trunk lid harness out from the cabin 3 Disconnect the hooks which secure the trunk lid harness to...

Page 797: ...A6E772052610W02 1 Disconnect the negative battery cable 2 Remove the trunk lid trim 3 To remove the trunk lid outer handle and trunk lid key cylinder remove the rear finisher 4 Disassemble in the orde...

Page 798: ...r Clearance a 2 5 4 5 mm 0 10 0 18 in b 1 0 1 0 mm 0 04 0 04 in c 4 0 8 0 mm 0 16 0 31 in 3 Tighten the bolts or screws End Of Sie STAY DAMPER DISPOSAL A6E772052610W04 Note The gas in the stay damper...

Page 799: ...attached to the liftgate to the 1 direction shown in the figure and then detach the fit Then remove the connector toward the 2 direction shown in the figure 4 Disconnect the vehicle harness connector...

Page 800: ...LIFTGATE S 43 S 9 To remove the stay damper remove the bolt B 10 Install in the reverse order of removal End Of Sie A6E7722W001...

Page 801: ...the stud ball and the stay damper 5 Disassemble in the order indicated in the table 6 Assemble in the reverse order of disassembly End Of Sie STAY DAMPER DISPOSAL A6E772262620W01 1 Referring to proced...

Page 802: ...loosen the liftgate hinge installation bolts or the liftgate striker installation screws and reposition the liftgate Clearance a 3 0 7 0 mm 0 12 0 28 in b 1 0 3 4 mm 0 04 013 in c 2 8 5 2 mm 0 11 0 2...

Page 803: ...D 7 Remove the rear seat installation bolts front side then lift the rear seat cushion R H D 5HB 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 5 Adjust the fue...

Page 804: ...to disengage from the bumper slider Caution If only one side of the front bumper is disengaged from the bumper slider and the bumper falls it could be damaged When disengaging the front bumper from th...

Page 805: ...le 2 Assemble in the reverse order of disassembly End Of Sie BUMPER REINFORCEMENT REMOVAL INSTALLATION A6E772650031W03 1 Disconnect the negative battery cable 2 Remove the front bumper See S 47 FRONT...

Page 806: ...r slider and the bumper falls it could be damaged When disengaging the rear bumper from the slider secure the bumper so that it does not fall Rear Bumper Installation Note 1 Spread the rear bumper end...

Page 807: ...l the radiator grille outward and remove from the front bumper 3 Install in the reverse order of removal End Of Sie COWL GRILLE REMOVAL INSTALLATION A6E772850790W01 1 Remove the windshield wiper arm a...

Page 808: ...he rear flap 3 Install in the reverse order of removal End Of Sie REAR DOOR GARNISH REMOVAL A6E772850030W01 1 Disengage the door garnish clips using a fastener remover 2 While cutting the double sided...

Page 809: ...rease or dirt from the adhesion surface of the rear door garnish and the body 3 Apply primer to the bonding area of the rear door garnish 4 Attach double sided adhesive tape to the rear door garnish a...

Page 810: ...mm 0 11 in e 3 0 mm 0 11 in f 1 0 3 0 mm 0 04 0 11 in g 5 0 mm 0 19 in h 2 0 mm 0 07 in 4 Peel off the backing paper from the double sided adhesive tape and attach the side protector onto the body as...

Page 811: ...AR SPOILER REMOVAL INSTALLATION A6E772851920W02 1 Remove the trunk lid trim 4SD 2 Remove the liftgate lower trim 5HB 3 Remove the bolts 4 Disconnect the high mount brake light connector 4SD 5 Remove t...

Page 812: ...of the front beltline molding in direction 2 along the direction 1 shown in the figure and remove it from the body End Of Sie FRONT BELTLINE MOLDING INSTALLATION A6E773050640W02 1 Press the clip into...

Page 813: ...n the figure and remove it from the body 3 Pull the C section upward and remove the clip Then remove the front beltline molding End Of Sie REAR BELTLINE MOLDING INSTALLATION A6E773050660W02 1 Press th...

Page 814: ...G INSTALLATION A6E773050620W02 1 Attach the roof molding to the T stud at the A section 2 Press in the roof molding along the direction 1 shown in the figure and attach it to the clip A at the B secti...

Page 815: ...the order indicated in the table 2 Assemble in the reverse order of disassembly Outside Mirror Glass Disassembly Note 1 Press area A of the glass so that area B moves toward you 2 Insert a screwdriver...

Page 816: ...ISASSEMBLY ASSEMBLY TYPE B A6E773269100W01 Mirror Glass Removal 1 Press area A of the mirror glass so that area B moves outward 2 Disengage clip A while lifting up the inside of the mirror glass holde...

Page 817: ...on the mirror garnish against the mirror body in the direction of the arrow shown in the figure and insert the mirror garnish clips 6 locations into the mirror body 2 Install the mirror garnish so tha...

Page 818: ...e 2 Remove the front door trim 3 Remove the screws and the power outside mirror switch 4 Install in the reverse order of removal End Of Sie POWER OUTSIDE MIRROR SWITCH INSPECTION A6E773266600W02 1 Ins...

Page 819: ...OUTSIDE MIRROR S 60 2 THIS PAGE IS INTENTIONALLY LEFT BLANK End Of Sie...

Page 820: ...nto the base End Of Sie BASE REMOVAL A6E773469240W01 1 Remove the rearview mirror 2 Wind each end of a wire around a bar Warning Using a SST piano wire with bare hands can cause injury Always wear glo...

Page 821: ...ply a height of 3 0 mm 0 12 in sealant to the base Note Use only glass primer on the glass and body primer on the base Allow the primer to dry for approximately 30 minutes 5 Center the base in the cer...

Page 822: ...completely End Of Sie FILAMENT INSPECTION A6E773663930W02 1 Turn the ignition switch to ON position 2 Turn the rear window defroster switch on Caution Directly touching the rear window defroster filam...

Page 823: ...shield molding is a replacement part Not Reusing Windshield 1 Remove the base Note For the areas of the sealant that are difficult to cut use a SST piano wire and follow the procedure under Reusing Wi...

Page 824: ...900W02 Caution To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed open all of the windows and leave them open until the sealant has hardened 1...

Page 825: ...glass primer on the glass and body primer on the body and the molding Allow it to dry for approximately 30 minutes Caution Keep the area free of dirt and grease and do not touch the surface or the pr...

Page 826: ...stall the interior light See T 48 FRONT MAP LIGHT REMOVAL INSTALLATION 15 Allow the sealant to harden completely Sealant hardening time 24 hours End Of Sie QUARTER WINDOW GLASS REMOVAL INSTALLATION A6...

Page 827: ...to protect it from damage 4 Cut the lip of the rear window molding using a razor Warning Using a razor with bare hands can cause injury Always wear gloves when using a razor Note The rear window moldi...

Page 828: ...iding pins from the inside of the vehicle using an awl 2 Pass the SST piano wire through the hole Warning Using a SST piano wire with bare hands can cause injury Always wear gloves when using a SST pi...

Page 829: ...lant has hardened 1 Cut away the old sealant using a razor so that 1 2 mm 0 04 0 07 in thickness of sealant remains around the circumference of the frame Warning Using a razor with bare hands can caus...

Page 830: ...imer on the body and the molding Allow it to dry for approximately 30 minutes Caution Keep the area free of dirt and grease and do not touch the surface or the primer may not properly bond to the surf...

Page 831: ...as shown in the figure 7 Set the position of the front windshield glass and insert a pin into the body Install the glass 8 Verify that the gap of the upper part is 7 3 mm 0 29 in and the A pillar part...

Page 832: ...eter of the glass 10 For the 4SD install the following parts 1 Install the headliner 2 Install the rear package trim 11 For the 5HB install the following points 1 Install the rear wiper motor 2 Instal...

Page 833: ...hem upward 5 Remove the deflector 6 Install in the reverse order of removal End Of Sie GLASS PANEL REMOVAL INSTALLATION A6E774069810W01 1 Fully close the glass panel 2 Fully open the sunshade 3 Remove...

Page 834: ...nect the front drain hose from the sunroof frame 3 Remove the front drain hose from the clips 4 Pull the front drain hose into the room side 5 Remove the front drain hose End Of Sie FRONT DRAIN HOSE I...

Page 835: ...the headliner always make sure there is no interference with the rear drain hose Fix any problem if found 1 Apply soapy water to the rear drain hose inserting area 2 Insert one end the wider side of...

Page 836: ...ve the deflector 3 Remove the glass panel 4 Disassemble in the order indicated in the table 5 Assemble in the reverse order of disassembly A6E7740W005 A6E7740W001 1 Drip rail 2 Position plate 3 Slider...

Page 837: ...Note 1 Slide the guide rearward and remove it from the sunroof frame Decoration Link Assembly Note 1 Set the pin in the decoration link Guide Assembly Note 1 Move the guide by hand until it comes to t...

Page 838: ...n switch to ON position 5 Press the CLOSE side of the slide switch until the sunroof motor stops 6 Disconnect the sunroof switch connector 7 Install the screws and then install the sunroof motor 8 Ins...

Page 839: ...sted under Action and the related wiring harnesses If the parts and wiring harnesses are okay but the system still does not work properly replace the sunroof relay 5 Connect the negative battery cable...

Page 840: ...ND Under any condition inspect for continuity to ground Yes Inspect related harness 1H Tilt up Sunroof switch Sunroof is tilting up Including position when fully closed 0 Inspect sunroof switch See S...

Page 841: ...with the wire type climate control unit disconnect the wires for the front A C unit See to U 44 CLIMATE CONTROL UNIT REMOVAL See to U 45 CLIMATE CONTROL UNIT INSTALLATION 14 Disconnect the dashboard...

Page 842: ...e order indicated in the table 6 Assemble in the reverse order of disassembly End Of Sie SIDE PANEL REMOVAL INSTALLATION A6E774264960W01 1 Disengage clips using a tape wrapped flathead screwdriver 2 P...

Page 843: ...moval End Of Sie METER HOOD REMOVAL INSTALLATION A6E774255420W01 1 Remove the screws 2 Pull the meter hood toward you then detach the column cover 3 Install in the reverse order of removal End Of Sie...

Page 844: ...unit connector 6 Install in the reverse order of removal End Of Sie GLOVE COMPARTMENT REMOVAL INSTALLATION A6E774264030W02 1 Pull the stay damper to the direction shown in the figure Then detach the f...

Page 845: ...6 Install in the reverse order of removal Applied VIN assumed JMZ GG12 190207 JMZ GG14 190207 JMZ GY19 137242 JMZ GY89 137242 1 For MT vehicle remove the shift lever knob 2 Rotate the wiring harness c...

Page 846: ...he reverse order of disassembly End Of Sie DASHBOARD AND CONSOLE 1 Console lid only large console box 2 Box 3 Rear ashtray case 4 Bracket 5 Console 6 Console cover 7 Box storage 8 Lock No 1 9 Inner co...

Page 847: ...upward then disengage clip B from the A pillar trim 2 5 Pull clip B out then rotate 45 6 Remove clip B from the grommet by pulling it toward you End Of Sie A PILLAR TRIM INSTALLATION A6E774468160W02 1...

Page 848: ...he upper anchor of the front seat belt 2 Remove the B pillar lower trim 3 Turn the seaming welt over 4 Pull the B pillar upper trim toward you then disengage clip B and pin C from the body 5 Disengage...

Page 849: ...3 Remove the cap using a fastener remover and remove the bolt with curtain air bag system 4 Disengage clips A and clip B using a fastener remover 5 Pull the C pillar trim forward then disengage hook C...

Page 850: ...h connector and the power window main switch connector driver s side or power window subswitch connector passenger s side 10 Remove the courtesy light 11 Remove the front door trim 12 Remove the switc...

Page 851: ...N A6E774468760W01 4SD 1 Remove the rear scuff plate 2 Remove the rear seat side 3 Remove the fastener 4 Pull the tire house trim upward then disengage clips A from the body and remove the tire house t...

Page 852: ...reverse order of removal End Of Sie TRUNK SIDE TRIM REMOVAL INSTALLATION A6E774468860W01 4SD 1 Remove the trunk end trim 2 Remove the fasteners then remove the trunk side trim 3 Install in the revers...

Page 853: ...or LH only 7 Install in the reverse order of removal End Of Sie TRUNK LID TRIM REMOVAL INSTALLATION A6E774458800W01 1 Pull the handle toward you then remove the handle 2 Remove the fasteners then remo...

Page 854: ...REMOVAL INSTALLATION A6E774468930W01 1 Pull the liftgate upper trim toward you then disengage clips A and pin B from the body 2 Remove the liftgate upper trim 3 Install in the reverse order of removal...

Page 855: ...side trim 6 Install in the reverse order of removal End Of Sie LIFTGATE LOWER TRIM REMOVAL INSTALLATION A6E774468960W01 1 Remove the liftgate upper trim 2 Remove the liftgate side trim 3 Pull the hand...

Page 856: ...See T 48 FRONT MAP LIGHT REMOVAL INSTALLATION See T 49 REAR MAP LIGHT REMOVAL INSTALLATION 8 Remove the sunvisors 9 Remove the assist handle 10 Disconnect the roof harness connector remove the clip a...

Page 857: ...pad 3 Install in the reverse order of removal End Of Sie ASSIST HANDLE REMOVAL INSTALLATION A6E774669440W01 1 Insert a screwdriver into the assist handle notch and remove the assist handle cover 2 Pul...

Page 858: ...INSTALLATION A6E774669270W01 1 Remove the screws then the sunvisor 2 Disengage the center adapter sunvisor stopper from the body using a fastener remover 3 Install in the reverse order of removal End...

Page 859: ...uff plates 6 Remove the console 7 Remove the front side trims 8 Remove the B pillar lower trims 9 Remove the lower anchor of the front seat belt installation bolts 10 Remove the tire house trim 5HB 11...

Page 860: ...nd by hand If this occurs the ELR will not work properly Therefore do not disassemble the retractor 1 Turn the ignition switch to LOCK position 2 Disconnect the negative battery cable and wait for mor...

Page 861: ...in the reverse order of removal 5HB Note Rear side seat belts are embedded in the rear seat back See rear seat disassembly assembly remove install the rear center seat belt End Of Sie REAR CENTER SEAT...

Page 862: ...rocedure for vehicles with seat belt warning 1 Disconnect the negative battery cable 2 Remove the front seat 3 Disconnect the buckle switch connector 2 Perform the following procedure for vehicles wit...

Page 863: ...the belt slowly retracts If no sound is heard the lock mode has not changed to ALR If necessary repeat the above Step 1 If not as specified replace the seat belt 3 Verify that the belt locks when pul...

Page 864: ...nspect for continuity between the buckle switch terminals using an ohmmeter If not as specified replace the front buckle End Of Sie CHILD RESTRAINT SEAT ANCHOR REMOVAL INSTALLATION A6E77505777ZW01 1 R...

Page 865: ...y injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling the front seat See T 117 SERVICE WARNINGS 1 Turn the ignition switch to the LOCK position 2 Disconnect the negative battery cable and...

Page 866: ...the order indicated in the table 4 Assemble in the reverse order of disassembly Driver s Seat Normal Seat A6E7752W017 1 Headrest 2 Lumber support lever See S 109 Lumber support lever disassembly note...

Page 867: ...ob 5 Side cover See S 109 Side cover disassembly note 6 Power seat switch 7 Reverce cover 8 Front cover No 1 9 Front cover No 2 10 Front buckle 11 Pole guide 12 Seat back trim 13 Seat warmer unit Euro...

Page 868: ...bag system which may seriously injure you A6E7752W003 1 Headrest 2 Recliner lever 3 Side cover See S 109 Side cover disassembly note 4 Reverse cover 5 Front buckle 6 Pole guide 7 Seat back trim 8 Seat...

Page 869: ...n part with rag Recliner dial disassembly note 1 Remove the pin from the recliner dial installation part with rag Side cover disassembly note 1 Remove the screws 2 Disengage the clips 3 Lift the side...

Page 870: ...d Of Sie REAR SEAT REMOVAL INSTALLATION A6E775257200W01 4SD 1 Remove in the order indicated in the table 2 Install in the reverse order of removal A6E7752W006 1 Rear seat cushion 2 Rear side seat 3 Re...

Page 871: ...2 Install in the reverse order of removal Remote wire removal note 1 Turn over the trunk floor mat 2 Remove the case 3 Remove the remote wire A6E7752W012 1 Remote wire See S 111 Remote wire removal n...

Page 872: ...e installation bolts End Of Sie REAR SEAT DISASSEMBLY ASSEMBLY A6E775257200W02 4SD 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly A6E7752W013 A6E7752W...

Page 873: ...Hinge cover 3 Seat cushion trim 4 Seat cushion pad 5 Seat cushion frame 6 Remote button cover 7 Seat back catch cover 8 Child seat anchor cover 9 Seat back board 10 Pole guide 11 Remote button 12 Arm...

Page 874: ...icated in the table 3 Install in the reverse order of removal 5HB 1 To remove the remote wire remove the trunk side upper trim and trunk side trim 2 Remove in the order indicated in the table 3 Instal...

Page 875: ...emove the seat back striker 5 Install in the reverse order of removal End Of Sie POWER SEAT SWITCH INSPECTION A6E775257155W01 1 Disconnect the power seat switch connector 2 Disconnect the rear tilt mo...

Page 876: ...INSPECTION A6E775288662W01 1 Disconnect the slide motor connector 2 Inspect the slide motor operation when B is applied to the terminals as shown If not as specified replace the seat cushion frame End...

Page 877: ...moval Note 1 Squeeze the tabs of seat warmer switch and pull it forward to remove it End Of Sie SEAT WARMER SWITCH INSPECTION A6E775259000W02 1 Remove the seat warmer switch 2 Inspect for continuity b...

Page 878: ...mostat of the seat warmer unit on seat cushion 4 When the indication on the ohmmeter is no continuity turn off the dryer then use a thermometer to measure the temperature of the thermostat 5 Verify th...

Page 879: ...ve in the order indicated in the table 6 Install in the reverse order of removal End Of Sie COWL PANEL REMOVAL INSTALLATION A6E775453580W01 1 Remove the windshield wiper arm and blade See T 57 WINDSHI...

Page 880: ...ess can cause wiring to become pinched between parts The connector joints points of vibration and places where wire harnesses pass through the firewall body panels etc are the major areas to be checke...

Page 881: ...doors in manual mode Does only driver side front window go up and down Yes Manual mode function is normal Go to automatic mode function inspection No Replace power window main switch then go to autom...

Page 882: ...finger continuously depressing power window main switch window should go down within approximately 42 seconds from ignition switch OFF position Does driver side front window go down Yes Go to next ste...

Page 883: ...t reverse even when encountering a foreign object in its path See S 126 NO 2 DRIVER SIDE FRONT WINDOW DOES NOT REVERSE EVEN WHEN ENCOUNTERING A FOREIGN OBJECT IN ITS PATH 3 Driver side front window re...

Page 884: ...UITY Turn ignition switch to LOCK position Disconnect power window main switch connector Is there continuity between the following power window main switch connector terminals and driver side front po...

Page 885: ...l 2B position sensor 2 signal and driver side front power window motor connector terminal G position sensor 2 signal Yes Go to next step No Repair wiring harness between power window main switch and d...

Page 886: ...HECK FOR CUSTOMER COMPLAINT Did customer complain that driver side front window did not reverse when nearing complete close Yes System normal Explain to customer that automatic window return power win...

Page 887: ...No Apply lubricant mineral oil 5 INSPECT INSTALLATION OF DRIVER SIDE FRONT POWER WINDOW SYSTEM COMPONENTS Are the following parts properly installed Driver side front door glass Driver side power win...

Page 888: ...ENTRY SYSTEM FOREWORD A6E778269000W01 Go to troubleshooting after identifying the specific malfunction by doing a keyless entry system preliminary inspection Flowchart End Of Sie TROUBLESHOOTING KEYL...

Page 889: ...End Of Sie KEYLESS ENTRY SYSTEM PRELIMINARY INSPECTION A6E778269000W03 Perform the following preliminary inspection before troubleshooting A6E7782W001 STEP INSPECTION ACTION 1 Is system an after marke...

Page 890: ...mote engine starter TV etc Yes Disconnect after market electrical part connectors and attempt to lock unlock doors with transmitter If system operates After market electrical parts are interfering wit...

Page 891: ...cylinder switch system POSSIBLE CAUSE Malfunction in hazard warning light system Hazard warning light circuit Door lock timer unit malfunction Malfunction in wiring harness between door lock timer uni...

Page 892: ...door lock timer unit ground circuit POSSIBLE CAUSE Malfunction in IG1 B signal circuit of door lock timer unit Door lock timer unit power supply fuse malfunction Malfunction in wiring harness between...

Page 893: ...door lock timer unit and reprogram door lock timer unit ID code then go to next step No Repair wiring harness between door lock timer unit and door switch es cargo compartment light switch then go to...

Page 894: ...eyless entry system preliminary inspection 6 CHECK TO SEE WHETHER MALFUNCTION IS IN TRANSMITTER BATTERY OR ELSEWHERE Replace with a known good transmitter battery Does keyless entry system operate pro...

Page 895: ...ARD COMBINATION LIGHT REMOVAL INSTALLATION T 35 HIGH MOUNT BRAKE LIGHT REMOVAL INSTALLATION T 36 LICENSE PLATE LIGHT REMOVAL INSTALLATION T 37 COMBINATION SWITCH REMOVAL INSTALLATION T 37 COMBINATION...

Page 896: ...NER NOZZLE CLEANING T 70 HEADLIGHT CLEANER HOSE REMOVAL INSTALLATION T 71 HEADLIGHT CLEANER SWITCH REMOVAL INSTALLATION T 71 HEADLIGHT CLEANER SWITCH INSPECTION T 71 WARNING AND INDICATOR SYSTEM T 72...

Page 897: ...TIPLEX COMMUNICATION SYSTEM T 140 1 MULTIPLEX COMMUNICATION SYSTEM T 140 1 DTC TABLE T 142 PID DATA MONITOR TABLE T 142 PROCEDURES FOR DETERMINING THE LOCATION OF A MALFUNCTION T 142 DTC U0073 U1900 U...

Page 898: ...3 B1886 T 203 DTC B1884 B1890 T 205 DTC B1913 B1916 B1932 B1934 T 208 DTC B1913 B1925 B1933 B1935 T 210 DTC B1921 T 211 DTC B1992 B1993 B1994 B1995 T 212 DTC B1996 B1997 B1998 B1999 T 213 DTC B2228 B2...

Page 899: ...witch See T 20 IGNITION SWITCH REMOVAL INSTALLATION See T 20 IGNITION SWITCH INSPECTION 4 Key reminder switch See T 21 KEY REMINDER SWITCH REMOVAL INSTALLATION See T 21 KEY REMINDER SWITCH INSPECTION...

Page 900: ...24 RELAY INSPECTION 13 Rear fog light relay See T 24 RELAY INSPECTION 14 A C relay See T 24 RELAY INSPECTION 15 Main relay See T 24 RELAY INSPECTION 16 Headlight relay See T 24 RELAY INSPECTION 17 TNS...

Page 901: ...ONFIGURATION 8 Front side turn light See T 33 FRONT SIDE TURN LIGHT REMOVAL INSTALLATION 9 Front auto leveling sensor See T 32 FRONT AUTO LEVELING SENSOR REMOVAL INSTALLATION See T 31 HEADLIGHT ZEROSE...

Page 902: ...INSTALLATION See T 46 RUNNING LIGHT UNIT INSPECTION A6E8112W162 1 Rear combination light See T 35 REAR COMBINATION LIGHT REMOVAL INSTALLATION 2 Inboard combination light See T 35 INBOARD COMBINATION...

Page 903: ...OMPARTMENT LIGHT BULB REMOVAL INSTALLATION See T 51 TRUNK COMPARTMENT LIGHT SWITCH INSPECTION 6 Trunk compartment light switch See T 51 TRUNK COMPARTMENT LIGHT SWITCH INSPECTION 7 Courtesy light See T...

Page 904: ...See T 56 WINDSHIELD WIPER MOTOR REMOVAL INSTALLATION See T 56 WINDSHIELD WIPER MOTOR DISASSEMBLY ASSEMBLY See T 56 WINDSHIELD WIPER MOTOR INSPECTION 3 Windshield washer nozzle See T 60 WINDSHIELD WASH...

Page 905: ...nozzle See T 70 HEADLIGHT CLEANER NOZZLE REMOVAL INSTALLATION See T 70 HEADLIGHT CLEANER NOZZLE ADJUSTMENT See T 70 HEADLIGHT CLEANER NOZZLE CLEANING 13 Headlight cleaner hose See T 71 HEADLIGHT CLEA...

Page 906: ...SASSEMBLY ASSEMBLY See T 73 INSTRUMENT CLUSTER INSPECTION See T 74 INSTRUMENT CLUSTER REPAIR See T 75 INSTRUMENT CLUSTER INPUT OUTPUT CHECK MODE 2 Fuel gauge sender unit See T 83 FUEL GAUGE SENDER UNI...

Page 907: ...ATION See T 86 THEFT DETERRENT CONTROL MODULE INSPECTION 2 Bonnet switch See T 85 BONNET SWITCH INSPECTION 3 Intruder sensor Vehicle with sliding sunroof See T 89 INTRUDER SENSOR REMOVAL INSTALLATION...

Page 908: ...IMMOBILIZER SYSTEM A6E810067000W01 End Of Sie A6E8122W004 1 Coil See T 90 COIL REMOVAL INSTALLATION 2 Key transponder See T 90 IMMOBILIZER SYSTEM REPROGRAM PROCEDURE 3 PCM See T 90 IMMOBILIZER SYSTEM...

Page 909: ...ION See T 103 TWEETER INSPECTION 5 Woofer See T 103 WOOFER REMOVAL INSTALLATION See T 104 WOOFER INSPECTION 6 Center roof antenna See T 107 CENTER ROOF ANTENNA REMOVAL INSTALLATION See T 107 CENTER RO...

Page 910: ...AL INSTALLATION 4 Audio unit See T 93 ANTI THEFT SYSTEM See T 96 CENTER PANEL MODULE REMOVAL INSTALLATION See T 97 CENTER PANEL MODULE DISASSEMBLY ASSEMBLY See T 97 AUDIO UNIT DISASSEMBLY ASSEMBLY 5 F...

Page 911: ...ator See T 110 CRUISE ACTUATOR REMOVAL INSTALLATION See T 110 CRUISE ACTUATOR INSPECTION 2 Actuator cable See T 112 ACTUATOR CABLE REMOVAL See T 114 ACTUATOR CABLE INSTALLATION 3 Cruise control switch...

Page 912: ...LT DEPLOYMENT PROCEDURES 4 Curtain air bag module See T 122 CURTAIN AIR BAG MODULE REMOVAL INSTALLATION See T 127 AIR BAG MODULE AND PRE TENSIONER SEAT BELT DEPLOYMENT PROCEDURES 5 Pre tensioner seat...

Page 913: ...TION A6E811066761W01 1 Disconnect the negative battery cable 2 Remove the main fuse block cover 3 Remove in the order indicated in the table 4 Install in the reverse order of removal Bolt Removal Note...

Page 914: ...cover See S 84 COLUMN COVER REMOVAL INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order of removal End Of Sie IGNITION SWITCH INSPECTION A6E811066151W02 1 Disconn...

Page 915: ...cover See S 84 COLUMN COVER REMOVAL INSTALLATION 3 Disconnect the key reminder switch connector 4 Inspect for continuity between the key reminder switch terminals using an ohmmeter If not as specified...

Page 916: ...ween the socket and the ring protrusion 5 While twisting the ring protrusion with the screwdriver push out and remove the socket Ring Removal Note 1 Pull the ring forward while compressing the hooks E...

Page 917: ...lay 3 Cooling fan relay No 3 4 Stater relay 5 Cooling fan relay No 4 6 Woofer relay 7 Rear window defroster relay 8 Rear fog light relay 9 A C relay 10 Main relay 11 Headlight relay 12 TNS relay 13 Co...

Page 918: ...not as specified replace the relay Terminal type Parts name Four terminal Type A Main relay Fuel pump relay Stater relay TNS relay Front fog light relay Rear fog light relay Horn relay Headlight clean...

Page 919: ...ers or a circuit tester When the headlights are on high voltage flows around the socket and bulb When turning on the discharge headlights while working always leave the headlights in the vehicle insta...

Page 920: ...ting condition 1 Disconnect the negative battery cable 2 Remove the front bumper See S 47 FRONT BUMPER REMOVAL INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order...

Page 921: ...hten them Note If the adjusting screws are tightened first then loosened they will continue to loosen when the vehicle is in motion and may cause the headlights to become misaligned 12 Turn the adjust...

Page 922: ...ecome misaligned End Of Sie HEADLIGHT BULB REMOVAL INSTALLATION A6E811251030W02 Low beam Halogen type 1 Disconnect the negative battery cable 2 Remove the fasteners then pull back the mudguard 3 Remov...

Page 923: ...s life will be shortened When replacing the bulb hold the metal flange not the glass 4 Install in the reverse order of removal High beam 1 Disconnect the negative battery cable 2 Remove in the order...

Page 924: ...le 3 Remove the front combination light See T 26 FRONT COMBINATION LIGHT REMOVAL INSTALLATION 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 Perform the headl...

Page 925: ...After the screen appears select LHID under Modules from the cascading menu 9 After the next screen appears select CALAXLSN 10 On the graphic display that appears press the icon near the top right of t...

Page 926: ...djust the headlight zeroset See T 31 HEADLIGHT ZEROSET End Of Sie REAR AUTO LEVELING SENSOR REMOVAL INSTALLATION A6E811251030W07 1 Disconnect the negative battery cable 2 Jack up the vehicle 3 Remove...

Page 927: ...1 Disconnect the negative battery cable 2 Remove in the order indicated in the table 3 Install in the reverse order of removal End Of Sie FRONT SIDE TURN LIGHT REMOVAL INSTALLATION A6E811268370W01 1...

Page 928: ...will continue to loosen when the vehicle is in motion and may cause the front fog lights to become misaligned End Of Sie FRONT FOG LIGHT BULB REMOVAL INSTALLATION A6E811251680W02 1 Disconnect the neg...

Page 929: ...ID TRIM REMOVAL INSTALLATION See S 95 LIFTGATE LOWER TRIM REMOVAL INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order of removal Inboard Combination Light Installa...

Page 930: ...n the order indicated in the table 3 Install in the reverse order of removal Rear spoiler type 1 Disconnect the negative battery cable 2 Remove the rear spoiler See S 54 REAR SPOILER REMOVAL INSTALLAT...

Page 931: ...SWITCH REMOVAL INSTALLATION A6E811266120W01 1 Disconnect the negative battery cable 2 Remove the driver side air bag module See T 120 DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 3 Remove the stee...

Page 932: ...s may result in a malfunction of the steering angle sensor However remove it only when replacing the clock spring as a single unit by referring to CLOCK SPRING REMOVAL INSTALLATION See T 125 CLOCK SPR...

Page 933: ...n the steering wheel to the right and left and verify that the voltage and pulses at the terminals are as shown in the figure If not as specified replace the body of the combination switch End Of Sie...

Page 934: ...ch LH side 1 Remove the light switch See T 39 LIGHT SWITCH REMOVAL INSTALLATION 2 Inspect for continuity between the light switch terminals using an ohmmeter If not as specified replace the light swit...

Page 935: ...continuity between the light switch terminals using an ohmmeter If not as specified replace the light switch Headlight switch Turn switch End Of Sie HAZARD WARNING SWITCH INSPECTION A6E811266401W01 1...

Page 936: ...t for continuity between the light switch terminals using an ohmmeter If not as specified replace the light switch Light switch RH side 1 Remove the light switch See T 39 LIGHT SWITCH REMOVAL INSTALLA...

Page 937: ...G SWITCH INSPECTION A6E811251030W09 1 Remove the headlight leveling switch See T 43 HEADLIGHT LEVELING SWITCH REMOVAL INSTALLATION 2 Inspect for continuity between the headlight leveling switch termin...

Page 938: ...ed in the table 4 Install in the reverse order of removal End Of Sie FLASHER UNIT INSPECTION A6E811266830W02 1 Connect the connector to the flasher unit 2 Connect the negative battery cable 3 Measure...

Page 939: ...switch at on position Other Below 1 0 F Flasher unit ground GND Constant inspect for continuity to ground Yes Inspect GND G Turn signal flasher RH Turn signal light RH Turn signal light RH flashes Alt...

Page 940: ...ent cluster Panel control switch Headlight switch light at TNS or headlight position B Headlight switch light at OFF position Below 1 0 C Headlight relay high beam on off Headlight relay Ignition swit...

Page 941: ...osition B M Flash to pass on off Headlight switch dimmer switch Headlight switch light at OFF or TNS position No Inspect headlight switch See T 40 LIGHT SWITCH INSPECTION Inspect related harness Headl...

Page 942: ...liner and the front map light 2 Push the hooks to remove the front map light End Of Sie FRONT MAP LIGHT INSPECTION A6E811451310W02 1 Remove the front map light See T 48 FRONT MAP LIGHT REMOVAL INSTALL...

Page 943: ...etween the headliner and the rear map light 2 Push the hooks to remove the rear map light End Of Sie REAR MAP LIGHT INSPECTION A6E811451311W02 1 Remove the rear map light See T 49 REAR MAP LIGHT REMOV...

Page 944: ...cargo compartment light terminals using an ohmmeter If not as specified replace the cargo compartment light End Of Sie CARGO COMPARTMENT LIGHT SWITCH INSPECTION A6E811451442W01 1 Remove the liftgate...

Page 945: ...ove the lens 4 Remove the vanity mirror illumination bulb 5 Install in the reverse order of removal End Of Sie VANITY MIRROR ILLUMINATION INSPECTION A6E811469270W02 Applied VIN assumed JMZ GG12 202316...

Page 946: ...RIM REMOVAL INSTALLATION 2 Disconnect the trunk compartment light switch connector 3 Inspect for continuity between the trunk compartment light switch terminals using an ohmmeter If not as specified r...

Page 947: ...1 Remove the door switch See T 52 DOOR SWITCH REMOVAL INSTALLATION 2 Inspect for continuity between the door switch terminal and a body ground using an ohmmeter If not as specified replace the door sw...

Page 948: ...cated in the table 3 Install in the reverse order of removal End Of Sie PANEL LIGHT CONTROL SWITCH REMOVAL INSTALLATION A6E811466600W01 1 Disconnect the negative battery cable 2 Remove in the order in...

Page 949: ...lace the panel light control switch Terminal Voltage Table Reference Terminal Signal Connected to Test condition Voltage V Continuity Action A TNS Without running light system TNS relay Headlight swit...

Page 950: ...tch to either the TNS or headlight position 3 Set the panel light control switch to the brightest position 4 Verify that the pattern on the screen is as shown in the figure 5 Verify that the pattern o...

Page 951: ...motor and windshield wiper link End Of Sie WINDSHIELD WIPER MOTOR INSPECTION A6E811667340W03 L H D 1 Disconnect the windshield wiper motor connector 2 Connect battery positive voltage to terminal E o...

Page 952: ...ate at low speed again then stop in the park position If not as specified replace the windshield wiper motor End Of Sie WINDSHIELD WIPER ARM AND BLADE REMOVAL INSTALLATION A6E811667320W01 1 Remove in...

Page 953: ...ion 2 Set the windshield wiper arms height as shown End Of Sie WASHER TANK REMOVAL INSTALLATION A6E811667481W01 1 Disconnect the negative battery cable 2 Remove in the order indicated in the table 3 I...

Page 954: ...voltage to the motor terminal B and ground to the motor terminal A 4 Verify that the windshield washer motor operates If the motor does not operate replace the windshield washer motor End Of Sie WASHE...

Page 955: ...1 Remove the bonnet insulator 2 Remove the windshield washer hose from the windshield washer nozzle 3 Compress the hooks of the windshield washer nozzle 4 Pull the windshield washer nozzle out to rem...

Page 956: ...NK REMOVAL INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order of removal End Of Sie REAR WASHER MOTOR INSPECTION A6E811676672W02 1 Disconnect the negative battery...

Page 957: ...REAR WIPER ARM AND BLADE ADJUSTMENT End Of Sie REAR WIPER MOTOR INSPECTION A6E811667450W02 1 Disconnect the negative battery cable 2 Remove the liftgate lower trim See S 95 LIFTGATE LOWER TRIM REMOVA...

Page 958: ...in the table 2 Install in the reverse order of removal 3 Adjust the rear wiper arm and blade See T 64 REAR WIPER ARM AND BLADE ADJUSTMENT Rear Wiper Arm Installation Note 1 Clean the rear wiper arm co...

Page 959: ...asher hose from the rear washer nozzle 4 Compress the tabs of the rear washer nozzle 5 Pull the rear washer nozzle out to remove it 6 Install in the reverse order of removal 7 Adjust the rear washer n...

Page 960: ...sher hose No 2 from clip A 8 Remove clips B from the body 9 Remove rear washer hose No 2 and joint pipes B 10 Remove the C pillar trim See S 89 C PILLAR TRIM REMOVAL INSTALLATION 11 Remove the liftgat...

Page 961: ...not as specified in the Terminal Voltage List Reference inspect the parts under Action and related wiring harnesses 5 If the system does not work properly even though the parts or related wiring harn...

Page 962: ...ar wiper switch Ignition switch at ON position Rear wiper switch at INT position 0 Inspect R WIP 10 A fuse Inspect wiper and washer switch See T 68 WIPER AND WASHER SWITCH INSPECTION Inspect related h...

Page 963: ...the wiper and washer switch terminals using an ohmmeter If not as specified replace the wiper and washer switch With vehicle speed sensing type wipers 1 Remove the wiper and washer switch See T 67 WI...

Page 964: ...mal if the vehicle speed sensing wipers do not operate correctly replace the wiper and washer switch Rear Wiper and Washer Switch 1 Remove the wiper and washer switch See T 67 WIPER AND WASHER SWITCH...

Page 965: ...STALLATION 2 Disconnect the headlight cleaner hose See T 71 HEADLIGHT CLEANER HOSE REMOVAL INSTALLATION 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 5 Adjust...

Page 966: ...ert your hand from the lower side of the dashboard and squeeze the tabs of the headlight cleaner switch 2 Pull the headlight cleaner switch forward to remove it End Of Sie HEADLIGHT CLEANER SWITCH INS...

Page 967: ...ove in the order indicated in the table 7 Install in the reverse order of removal Instrument Cluster Removal Note 1 When removing the instrument cluster in order to prevent damage to the lens cover th...

Page 968: ...ion is within the allowable ranges shown below 3 Verify that fluctuation of the speedometer needle is within the allowable range If the speedometer needle does not move or the indication is outside of...

Page 969: ...etting it in the input output check mode DTC 23 Water Temperature Gauge 1 Inspect the water temperature gauge by setting it in the input output check mode DTC 25 End Of Sie INSTRUMENT CLUSTER REPAIR A...

Page 970: ...rotated while a code other than DTC 00 is display the input output check mode will be cancelled The diagnostic trouble codes can be fast forwarded by pushing and holding the odometer tripmeter switch...

Page 971: ...T 76 WARNING AND INDICATOR SYSTEM Operating Order A6E8118W009...

Page 972: ...TION INDICATION ACTION 1 Unfasten driver side seat belt Buckle switch on Go to next step Measure voltage at instrument cluster terminal 2G Is voltage 0 V If as specified replace instrument cluster If...

Page 973: ...s specified replace instrument cluster If not as specified inspect following parts Door switch Wiring harness Instrument cluster door switch 3 Open rear door on driver s side Door switch on Close rear...

Page 974: ...tage B If as specified replace instrument cluster If not as specified inspect following parts TNS relay Wiring harness Battery TNS relay instrument cluster 2 Turn headlight switch off TNS relay off Me...

Page 975: ...signal to fuel level warning light INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 16 Fuel level warning light turns on and off three times Fuel level warning light is o...

Page 976: ...er 3 Using SST Fuel and thermometer checker or resistor input 20 ohms to between instrument cluster terminals 2D and 2M Go to next step Other than stated above Replace instrument cluster 4 Using SST F...

Page 977: ...every 2 seconds H Center C H fixed Water temperature gauge is okay Other than stated above Replace instrument cluster Replace instrument cluster DTC 26 LCD indication INSPECTION INDICATION SITUATION A...

Page 978: ...f the float are as indicated in the figure If they are not as indicated replace the fuel gauge sender unit End Of Sie 2 Remove key from steering lock Key reminder switch off Measure voltage at instrum...

Page 979: ...mud guard 3 Remove in the order indicated in the table 4 Install in the reverse order of removal End Of Sie INFORMATION DISPLAY REMOVAL INSTALLATION A6E811855000W01 1 Disconnect the negative battery c...

Page 980: ...A and B using an ohmmeter If there is continuity replace the bonnet switch 6 Lock the bonnet lock using a flat head screwdriver or equivalent as shown 7 Check the no continuity between the bonnet swi...

Page 981: ...deterrent control module Terminal Voltage Table Reference 1 Screw 2 Connector 3 Theft deterrent control module A6E8120W001 Terminal Signal Connected to Test condition Voltage V continuity Action A B...

Page 982: ...h off key removed Below 1 0 N O Intruder sensor on off Intruder sensor Theft deterrentsystem pre arming or arming Alternates between below 1 0 and B Inspect related harness P Q Bonnet open closed Bonn...

Page 983: ...r door lock link switch locked inspect for continuity to ground No Inspect passenger s or rear door lock link switch See S 30 FRONT DOOR LOCK ACTUATOR INSPECTION See S 32 REAR DOOR LOCK ACTUATOR INSPE...

Page 984: ...f removal End Of Sie THEFT DETERRENT SIREN REMOVAL INSTALLATION A6E812000173W01 1 Disconnect the negative battery cable 2 Remove the left side trunk side trim 3 Remove in the order indicated in the ta...

Page 985: ...ngine Then perform the key replacement or addition reprogram procedure according to the valid key number To make a copy of the key or replace the immobilizer system component parts the key s and or PC...

Page 986: ...having to erase the key codes already registered If 8 keys have already been registered this procedure cannot be used to register a key To register a key under this condition it is necessary to first...

Page 987: ...roval See T 92 1 Security Access Procedure 2 Select Ignition Key Code Erase Note Do not select any other command from this menu 3 Turn key 1 to LOCK position for more than 1 second 4 Turn key 1 to ON...

Page 988: ...omer Spare Key Programming Enable Disable Enable Key registration can be performed without using the SST WDS Disable Key registration can only be performed using the SST WDS Note At the time of new ve...

Page 989: ...multaneously press channel button 6 for approximately 2 seconds until CODE appears on the display 3 Press the AUTO M button again then simultaneously press channel button 6 until bars appear on the di...

Page 990: ...nds or the canceling procedure will be canceled 1 Turn the ignition switch to ACC position and then turn off the audio unit 2 First press the AUTO M button then simultaneously press channel button 6 f...

Page 991: ...conds until bars appears on the display Note Perform Step 3 within 10 seconds after Step 2 3 Use channel buttons 1 4 to input the selected code number Press button 1 for the first digit 2 for the seco...

Page 992: ...eeder are not caught between the unit and dashboard If the harness or the antenna feeder is caught between the unit and dashboard it may cause trouble or malfunctions 7 Operate the anti theft system b...

Page 993: ...Sie AUDIO UNIT DISASSEMBLY ASSEMBLY A6E812466900W04 1 Remove the audio unit See T 97 CENTER PANEL MODULE DISASSEMBLY ASSEMBLY 2 Disassemble in the order indicated in the table 3 Assemble in the rever...

Page 994: ...on unit fixed in place install the bolt End Of Sie LCD UNIT REMOVAL INSTALLATION A6E812466902W02 1 Disconnect the negative battery cable 2 Remove the center panel module See T 96 CENTER PANEL MODULE R...

Page 995: ...and the cruise control switch use a common connector 1 Disconnect the negative battery cable 2 Remove the driver side air bag module See T 120 DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 3 Remove...

Page 996: ...ch connector 4 Measure the resistance and inspect for continuity between the cruise control switch terminals using an ohmmeter If not as specified replace the cruise control switch End Of Sie AUDIO AM...

Page 997: ...ched with the harness placed outside of the groove the wiring harness might be broken End Of Sie FRONT DOOR SPEAKER INSPECTION A6E812466960W02 1 Inspect for resistance between the front door speaker t...

Page 998: ...ached with the harness placed outside of the groove the wiring harness might be broken End Of Sie REAR DOOR SPEAKER INSPECTION A6E812466964W02 1 Inspect for resistance between the rear door speaker te...

Page 999: ...ot as specified replace the tweeter 2 To verify that the tweeter outputs sound apply voltage to the tweeter and release using a 1 5 V battery If not outputs sound replace the tweeter End Of Sie WOOFER...

Page 1000: ...r connector terminal A 4SD or C 5HB using a voltmeter If not as specified replace the related wiring haness 3 Inspect continuity between the woofer connector terminal B and body ground using an ohmmet...

Page 1001: ...e order indicated in the table 4 Install in the reverse order of removal End Of Sie NOISE FILTER INSPECTION A6E812466869W02 Brake Light Noise Filter 1 Inspect for resistance and continuity between the...

Page 1002: ...66869W03 4SD 1 Disconnect the negative battery cable 2 Remove the rear package trim 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 5HB 1 Disconnect the negative...

Page 1003: ...SPECTION A6E812466939W02 1 Verify that there is no continuity between the center roof antenna terminals A and C using an ohmmeter 2 Inspect for continuity between the center roof antenna terminals usi...

Page 1004: ...trument cluster 3 Remove in the order indicated in the table 4 Install in the reverse order of removal End Of Sie ANTENNA FEEDER LOCATION A6E812466941W01 End Of Sie 1 Connector 2 GPS antenna A6E8124W0...

Page 1005: ...tenna feeder terminals using an ohmmeter If not as specified replace the instrument panel harness End Of Sie REAR ANTENNA FEEDER INSPECTION A6E812466942W01 1 Verify that there is no continuity between...

Page 1006: ...02 1 Disconnect the cruise actuator connector 2 Measure the voltage continuity and resistance at the cruise actuator terminals as indicated below If not as specified inspect the parts listed under Act...

Page 1007: ...F 45 PCM INSPECTION Inspect related harness F MTX Clutch switch on off Clutch switch Inspect for continuity to ground Depress crutch switch Yes Inspect clutch switch Inspect related harness Other No A...

Page 1008: ...control main switch held at on 0 ohm Inspect cruise control switch See T 116 CRUISE CONTROL SWITCH INSPECTION Inspect related harness SET COAST switch held at on Approx 680 ohms RESUME ACCEL switch h...

Page 1009: ...tor cable from the bracket 7 Remove the end fitting of the actuator cable from the cruise actuator 8 Squeeze the hooks of the grommet and remove it from the cruise actuator 9 Remove the actuator cable...

Page 1010: ...shown by the arrow 3 Install the actuator cable to the cruise actuator Caution Due to the possibility of actuator cable damage make sure there is no twisting in the cable when installing 4 Install th...

Page 1011: ...le directly behind the spring two times 10 Turn the ratchet ring in the direction shown by the arrow to lock it 11 Slide the lock lever in the direction shown by the arrow to lock the adjuster 12 Inst...

Page 1012: ...he driver side air bag module See T 120 DRIVER SIDE AIR BAG MODULE REMOVAL INSTALLATION 3 Disconnect the cruise control switch connector 4 Inspect for resistance and continuity between the cruise cont...

Page 1013: ...n air bag system wiring harness can accidentally deploy the air bag module or pre tensioner seat belt which can cause serious injury If a problem is found in the system wiring replace the wiring harne...

Page 1014: ...lt in serious injury Therefore before connecting the connector firmly mount the control module to the vehicle For vehicles with a single point sensor once an air bag module is deployed due to an accid...

Page 1015: ...nd cause a serious injury Always replace the side air bag sensor with a new part The side air bag sensor cannot be bench checked or self checked Pre tensioner Seat Belt Inspection Inspecting a pre ten...

Page 1016: ...te deployment of inflator No 1 and 2 1 Turn the ignition switch to LOCK position 2 Disconnect the negative battery cable and wait for more than 1 minute 3 Remove in the order indicated in the table 4...

Page 1017: ...ition switch to ON position 7 Verify that the air bag system warning light illuminates for approximately 6 seconds and then goes off If the air bag system warning light does not operate in the manner...

Page 1018: ...ously injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag module See T 117 SERVICE WARNINGS 1 Turn the ignition switch to LOCK position 2 Disconnect the negative battery cable...

Page 1019: ...n the order indicated in the table 5 Install in the reverse order of removal 6 Turn the ignition switch to ON position 7 Verify that the air bag system warning light illuminates for approximately 6 se...

Page 1020: ...S UNIT CONFIGURATION 2 Turn the ignition switch to LOCK position 3 Disconnect the negative battery cable and wait for more than 1 minute 4 Partially peel off the floor covering 5 Remove in the order i...

Page 1021: ...Inspect the system using the on board diagnostic Clock Spring Installation Note Caution If the clock spring is not adjusted the spring wire in the clock spring will break due to overtension when the s...

Page 1022: ...2 Inspect for continuity between the clock spring terminals using an ohmmeter If not as specified replace the clock spring Note When the vehicle side connector of clock spring is disconnected the ter...

Page 1023: ...cle See T 131 Deployment Procedure for Outside of Vehicle Note When disposing of deployed air bag module and pre tensioner seat belt refer to the disposal procedure See T 139 AIR BAG MODULE AND PRE TE...

Page 1024: ...operated deployed properly This may cause serious injury because the air bag module may operate deploy accidentally If the two operation explosive sounds are not heard perform Step 8 again In case th...

Page 1025: ...oyment tool to operate deploy the air bag module both inflators Warning Verify that air bag module operation explosive sound occurs twice If no operation explosive sound was heard or a single operatio...

Page 1026: ...the positive battery terminal and the black clip to the negative battery terminal 5 Verify that the red light on the SST Deployment tool is illuminated 6 Make sure all persons are standing at least 6...

Page 1027: ...he SST Deployment tool to the SST Adapter harness 6 Connect the red clip of the SST Deployment tool to the positive battery terminal and the black clip to the negative battery terminal 7 Verify that t...

Page 1028: ...the negative battery terminal 6 Verify that the red light on the SST Deployment tool is illuminated 7 Make sure all persons are standing at least 6 m 20 ft from the vehicle 8 Press the activation swi...

Page 1029: ...ver side air bag module as shown in the figure 3 Place the driver side air bag module on the center of the tire wheel with the module facing up To secure the air bag module to the tire wheel wrap the...

Page 1030: ...ate deploy accidentally If the two operation explosive sounds are not heard perform Step 10 again In case that the two operation explosive sounds in total are not verified even though Step 10 is perfo...

Page 1031: ...he center of the tire 5 Stack the tire with the passenger side air bag module on top of two tires Stack another tire that has a wheel on top of the four tires 6 Tie all tires together with wire 7 Conn...

Page 1032: ...ould not have operated deployed properly This may cause serious injury because the air bag module may operate deploy accidentally If the two operation explosive sounds are not heard perform Step 11 ag...

Page 1033: ...s through the tire and around the bracket at least four times Warning If the air bag module is not properly installed to the tire serious injury may occur when the module is deployed When installing t...

Page 1034: ...Deployment tool to deploy the side air bag module Curtain air bag module 1 Remove the curtain air bag module See T 122 CURTAIN AIR BAG MODULE REMOVAL INSTALLATION 2 Secure the curtain air bag module i...

Page 1035: ...may occur when the module is deployed When installing the air bag module to the tire make sure the module is facing the downward 5 Connect the SST Adapter harness to the curtain air bag module as show...

Page 1036: ...r seat belt 1 Remove the pre tensioner seat belt See S 100 FRONT SEAT BELT REMOVAL INSTALLATION Warning If the pre tensioner seat belt is not properly installed to the tire serious injury may occur wh...

Page 1037: ...eat belt End Of Sie AIR BAG MODULE AND PRE TENSIONER SEAT BELT DISPOSAL PROCEDURES A6E813057000W02 Warning Before scrapping a vehicle with a live undeployed air bag module and pre tensioner seat belt...

Page 1038: ...ag module or pre tensioner seat belt in a plastic bag seal it and then dispose of it 3 Wash your hands after removing your gloves End Of Sie INSPECTION OF SST DEPLOYMENT TOOL A6E813001046W03 Use the S...

Page 1039: ...re any DTCs displayed Yes Are any DTCs other than the following displayed PCM U0073 U0121 U0155 ABS ABS TCS HU CM DSC HU CM Instrument cluster U1900 U2516 No END No No Yes Are any of the following DTC...

Page 1040: ...If there are two or more units that do not respond disconnect only one of the units Turn the ignition switch to the ON position Measure the voltage between DLC 2 terminals CAN_L and CAN_H Is the volt...

Page 1041: ...0073 U1900 U2516 U2516 CAN system wiring harness open and short circuit PID name definition Condition Specification Related module Terminal IC_MSG Missing message from the instrument cluster Present C...

Page 1042: ...ing the SST WDS or equivalent 2 Referring to the PID DATA MONITOR confirm the display status of the PID See T 142 PID DATA MONITOR TABLE 3 Referring to the following table determine the malfunctioning...

Page 1043: ...C Instrument cluster malfunction STEP INSPECTION ACTION 1 DETERMINING THE LOCATION OF A MALFUNCTION Determine the malfunctioning part of the CAN system See T 142 PROCEDURES FOR DETERMINING THE LOCATIO...

Page 1044: ...ABS TCS HU CM or DSC HU CM connector okay Yes Go to next step No Replace wiring harness 9 Is vehicle equipped with DSC Yes Go to next step No Go to Step 11 10 INSPECT WIRING HARNESS BETWEEN DSC HU CM...

Page 1045: ...t End Of Sie 14 INSPECT WIRING HARNESS BETWEEN PCM AND DSC HU CM Disconnect negative battery cable Disconnect DSC HU CM connector Inspect following wiring harness between PCM and DSC HU CM terminals f...

Page 1046: ...867000W02 DTCs are common for present and past malfunction diagnosis End Of Sie PID DATA MONITOR TABLE A6E818867000W03 LHID ON BOARD DIAGNOSTIC DISCHARGE HEADLIGHT DLC 2 A6E3970W002 DTC Description Pa...

Page 1047: ...ront combination light is malfunctioning STEP INSPECTION ACTION 1 Are DTCs B2388 and or B2389 indicated Yes Replace discharge headlight bulb See T 28 HEADLIGHT BULB REMOVAL INSTALLATION No Ignitor in...

Page 1048: ...DTC is displayed again replace discharge headlight bulb See T 28 HEADLIGHT BULB REMOVAL INSTALLATION No Replace discharge headlight bulb See T 28 HEADLIGHT BULB REMOVAL INSTALLATION DTC B2389 Discharg...

Page 1049: ...TEP INSPECTION ACTION 1 INSPECT CONNECTOR CONNECTION Check fit of discharge headlight control unit and headlight connectors Are installation condition and fit okay Yes Go to next step No After correct...

Page 1050: ...NIT REMOVAL INSTALLATION No Troubleshooting completed DTC B2393 Discharge headlight control unit output circuit malfunction DETECTION CONDITION Warning Incorrect servicing of the discharge headlight c...

Page 1051: ...connector 2 Turn the ignition switch to ON Engine OFF or start engine 3 Retrieve DTC by WDS or equivalent Clearing DTCs Procedures Using WDS or equivalent 1 After repairs have been made perform the re...

Page 1052: ...155 DTC B2616 B2619 Rear auto leveling sensor signal system See T 157 DTC B2619 B2626 Headlight zerosetting system for auto leveling control unit See T 158 DTC B2626 B2477 B2735 Headlight leveling ac...

Page 1053: ...ition Unit Condition Condition Specification Auto Leveling Control Unit Sub terminal CCNT Number of continuous codes DTC is detected 1 255 DTC is not detected 0 ONDEMDTC Number of on demand codes DTC...

Page 1054: ...eveling control unit always refer to Discharge headlight service warnings See T 25 DISCHARGE HEADLIGHT SERVICE WARNINGS Auto leveling control unit does not work properly POSSIBLE CAUSE Auto leveling c...

Page 1055: ...ock because the unit is integrated with the discharge headlight control unit Before servicing the auto leveling control unit always refer to Discharge headlight service warnings See T 25 DISCHARGE HEA...

Page 1056: ...ntinuity between the following connectors Auto leveling control unit main connector terminal I and headlight LH connector terminal 1F Auto leveling control unit sub connector terminal P and headlight...

Page 1057: ...tegrated with the discharge headlight control unit Before servicing the auto leveling control unit always refer to Discharge headlight service warnings See T 25 DISCHARGE HEADLIGHT SERVICE WARNINGS Op...

Page 1058: ...g control unit main connector 20 pin and headlight LH connector 4 pin Is there no continuity between the following connectors Headlight LH connector terminal 2B and auto leveling control unit main con...

Page 1059: ...ontrol unit always refer to Discharge headlight service warnings See T 25 DISCHARGE HEADLIGHT SERVICE WARNINGS Front auto leveling sensor or rear auto leveling sensor supply voltage 5 V which is gener...

Page 1060: ...connector Measure voltage at rear auto leveling sensor connector terminal D Is voltage approximately 5 V Yes Replace front auto leveling sensor See T 32 REAR AUTO LEVELING SENSOR REMOVAL INSTALLATION...

Page 1061: ...because the unit is integrated with the discharge headlight control unit Before servicing the auto leveling control unit always refer to Discharge headlight service warnings See T 25 DISCHARGE HEADLIG...

Page 1062: ...and headlight LH connector terminal 2B Front auto leveling sensor connector terminal B and headlight LH connector terminal 2A Yes Go to next step No Repair or replace wiring harness between front auto...

Page 1063: ...it in wiring harness between rear auto leveling sensor and headlight LH Headlight LH malfunction STEP INSPECTION ACTION 1 INSPECT REAR LEVELING SENSOR CONNECTION Check installation condition of rear a...

Page 1064: ...ector 20 pin and headlight LH connector 4 pin Is there continuity between the following connectors Auto leveling control unit main connector terminal G and headlight LH connector terminal 2D Auto leve...

Page 1065: ...ng actuator is abnormal POSSIBLE CAUSE Headlight leveling actuator malfunction Auto leveling control unit malfunction Headlight malfunction STEP INSPECTION ACTION 1 INSPECT CONNECTOR CONNECTION Check...

Page 1066: ...bject or electrical device is on the key ring The security light displays a DTC 10 times 1 Turn the ignition switch to ON position If there is any malfunction the security light flashes rapidly for ap...

Page 1067: ...ity light Security light flashing pattern WDS or equivalent 11 B1681 Coil signal is not received See T 162 SECURITY LIGHT DTC 11 WDS OR EQUIVALENT DTC B1681 12 B2103 Coil failure See T 163 SECURITY LI...

Page 1068: ...oltage at terminal B of coil connector Is voltage more than 8 V Yes Go to Step 7 No Go to next step 4 INSPECT COIL INPUT SIGNAL CIRCUIT Turn ignition switch to LOCK position Disconnect PCM connector T...

Page 1069: ...failure POSSIBLE CAUSE Defective Coil Poor connection of coil connector STEP INSPECTION ACTION INSPECT CONNECTOR CONNECTION Is connector of coil and PCM connected securely Yes Replace coil See T 90 C...

Page 1070: ...to next step 2 VERIFY DTC USING SST Does SST WDS or equivalent indicate DTC B1600 Yes Go to SECURITY LIGHT DTC 13 WDS OR EQUIVALENT B1600 No Go to next step 3 INSPECT PCM Erase key ID number using SST...

Page 1071: ...y ID number See T 90 IMMOBILIZER SYSTEM REPROGRAM PROCEDURE Go to next step No Go to next step 3 INSPECT PCM Erase key ID number using SST WDS and register key ID number See T 90 IMMOBILIZER SYSTEM RE...

Page 1072: ...ic procedure End Of Sie DTC B1342 PCM is defective POSSIBLE CAUSE Defective PCM STEP INSPECTION ACTION INSPECT PCM Clear DTCs with WDS or equivalent Does SST WDS or equivalent indicate DTC B1342 again...

Page 1073: ...replacement verify which supplier the module belongs to and enter in the Audio Repair Order Form Identification With Printed Numbers Label 1 Remove the audio unit 2 Verify the supplier name written o...

Page 1074: ...ommunication line See T 168 DTC 03 ER10 05 Er10 CD changer external type base unit communication line See T 169 DTC 05 ER10 06 Er10 CD changer upper module base unit communication line See T 169 DTC 0...

Page 1075: ...next step No Replace fuse 2 INSPECT BATTERY Measure battery voltage Is voltage 8 5 V 16 V Yes Go to next step No Battery is weak Inspect charge discharge system 3 INSPECT WIRING HARNESS BETWEEN BATTE...

Page 1076: ...Turn ignition switch to ACC or ON position and hold for 3 seconds or more Start on board diagnostic test mode Is DTC 00 Er10 displayed Yes Replace base unit and cassette deck No Troubleshooting comple...

Page 1077: ...Start on board diagnostic test mode Is DTC 05 Er10 displayed Yes Replace base unit and CD changer external type No Troubleshooting completed DTC 06 Er10 CD changer upper module base unit communication...

Page 1078: ...to next step 3 INSPECT MD PLAYER Clear DTC Turn ignition switch to ACC or ON position and hold for 3 seconds or more Start on board diagnostic test mode Is DTC 07 Er10 displayed Yes Replace base unit...

Page 1079: ...CD player DETECTION CONDITION Note When error occurs error message CHECK CD is displayed in the LCD Base unit detects CD reading error POSSIBLE CAUSE Defective CD scratches or dirt CD player malfuncti...

Page 1080: ...en go to next step 2 INSPECT CASSETTE DECK Clear DTC Insert cassette tape with no defect Play cassette tape for 20 seconds or more Start on board diagnostic test mode Is DTC 00 Er03 displayed Yes Repl...

Page 1081: ...reading error POSSIBLE CAUSE Defective CD scratches or dirt CD changer external type malfunction STEP INSPECTION ACTION 1 VERIFY WHETHER MALFUNCTION IS IN CD CHANGER OR OTHER PARTS Play all CD in mag...

Page 1082: ...track change again If CD changer changes tracks go to Step 3 If not replace CD changer upper module 2 INSPECT CD Inspect condition of CD where error has occurred Is CD okay Yes Go to next step No Repa...

Page 1083: ...and eject MD with no defect Start on board diagnostic test mode Is DTC 07 Er01 displayed Yes Replace MD player No Troubleshooting completed DTC 07 Er02 MD player DETECTION CONDITION Note When error oc...

Page 1084: ...r replace MD then go to next step 2 INSPECT MD PLAYER Clear DTC Insert and play MD for 12 seconds or more Start on board diagnostic test mode Is DTC 07 Er07 displayed Yes Replace MD player No Troubles...

Page 1085: ...n 2 for approximately 1 second 2 Inspect the radio reception condition according to the following table 3 Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist f...

Page 1086: ...to the following table 3 Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function End Of Sie Inspection Display Action Start audio amplifier external insp...

Page 1087: ...nds Operation mode is not on the following may be the cause of the malfunction Cruise actuator ignition power supply fuse Cruise set indicator light power supply fuse Cruise control switch Cruise cont...

Page 1088: ...cruise control main switch Operation Code List Inspection of Diagnostic Trouble Codes Foreword When performing an asterisked troubleshooting inspection shake the wiring harness and connectors while do...

Page 1089: ...SPECTION Is cruise control switch okay Yes Go to next step No Replace cruise control switch See T 115 CRUISE CONTROL SWITCH REMOVAL INSTALLATION 3 INSPECT CLOCK SPRING Inspect clock spring See T 126 C...

Page 1090: ...No Replace fuse after inspecting and repairing wiring harness 3 INSPECT WIRING HARNESS BETWEEN STOP 15 A FUSE AND BRAKE SWITCH FOR CONTINUITY Depress brake pedal Is voltage at brake switch connector t...

Page 1091: ...terminal F is not approximately 0 V POSSIBLE CAUSE Cruise actuator malfunction Starter relay malfunction ATX Clutch switch malfunction MTX TR switch malfunction ATX Open circuit in wiring harness bet...

Page 1092: ...or connector terminal A POSSIBLE CAUSE Cruise actuator malfunction DSC HU CM with ABS TCS HU CM Open or short circuit in wiring harness between ABS TCS cruise actuator and DSC HU CM without DSC ABS TC...

Page 1093: ...ndicated 6 The condition detection mode is canceled by turning the ignition switch to LOCK position or turning off the cruise control main switch Condition Code List Note When two or more DTCs are ind...

Page 1094: ...DTC 31 on board diagnostic again Even if no malfunction is detected in operation mode if DTC 05 is indicated in condition detection mode on board diagnostic replace cruise actuator See T 110 CRUISE A...

Page 1095: ...LATION No Repair wiring harness Cruise actuator Brake switch 2 DTC 11 Cruise control switch SET COAST switch DETECTION CONDITION Resistance detected between cruise actuator connector terminal J and gr...

Page 1096: ...on mode for DTCs 21 and 22 performed Yes Perform operation mode for DTCs 21 and 22 on board diagnostic again Even if no malfunction is detected in operation mode if DTC 13 is indicated in condition de...

Page 1097: ...ctive command mode Diagnostic DTC can be read cleared using the SST WDS or equivalent Note When the air bag system is malfunctioning turn the ignition switch to the ON position to display the current...

Page 1098: ...icable DTCs may be added to memory by removing or disconnecting the related parts Inspect only the DTCs that were indicated before inspecting When DTCs of present malfunction are no longer output afte...

Page 1099: ...or equivalent 3 Ensure that the customer s concern has been resolved PID Data Monitor and Record Procedure 1 Connect SST WDS or equivalent to the vehicle DLC 2 16 pin connector 2 Access and monitor PI...

Page 1100: ...bag system warning light is illuminated all the time 1 Air bag system warning light system circuit open See T 198 DTC B1869 B1870 Air bag system warning light is illuminated does not illuminate Air b...

Page 1101: ...211 DTC B1921 B1925 21 10 Passenger side air bag module inflator No 1 system circuit short to power supply See T 210 DTC B1913 B1925 B1933 B1935 B1932 19 11 Driver side air bag module inflator No 1 sy...

Page 1102: ...ort to power supply See T 217 DTC B2229 B2231 B2233 B2235 B2232 19 11 Driver side air bag module inflator No 2 system resistance high See T 215 DTC B2228 B2230 B2232 B2234 B2233 21 10 Passenger side a...

Page 1103: ...nication error See T 220 DTC B2444 U2017 U2018 44 7 Passenger side side air bag sensor system communication error See T 222 DTC B2445 U2018 DTC Malfunction location Page WDS or equivalent Air bag syst...

Page 1104: ...Related wiring harness normal NORMAL Related wiring harness circuit open OPEN Related wiring harness short to ground SHRT GND Related wiring harness short to power supply SHRT B 2V 2Y OD_DAB1_ST On d...

Page 1105: ...to power supply SHRT B 2I 2L PS_CURTN Passenger side curtain air bag module resistance ohm Under any condition 1 4 3 2 ohm 2A 2B PS_CURT_ST Passenger side curtain air bag module circuit state NORMAL...

Page 1106: ...or or damage the system When performing inspection always follow inspection procedure Malfunction in SAS unit inner circuit POSSIBLE CAUSE SAS unit malfunction ACTION Replace SAS unit See T 124 SAS UN...

Page 1107: ...ule connector Disconnect driver and passenger side curtain air bag module connectors Vehicles with curtain air bag Disconnect driver and passenger side side air bag module connectors Vehicles with sid...

Page 1108: ...cedure Malfunction in wiring harness between SAS unit and occupancy sensor Malfunction in occupancy sensor circuit POSSIBLE CAUSE Open or short circuit in wiring harness between METER IG 15 A fuse and...

Page 1109: ...als for short to ground short to power supply and open circuit 1I B Is wiring harness okay Yes Go to next step No Replace wiring harness 3 INSPECT WIRING HARNESS BETWEEN METER IG 15 A FUSE AND OCCUPAN...

Page 1110: ...at belt and SAS unit Driver side pre tensioner seat belt malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT DRIVER SIDE PRE TENSIONER SEAT BELT Check following PID DATA monitor using SS...

Page 1111: ...ted Yes Present malfunction diagnosis Replace SAS unit See T 124 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed No Troubleshooting completed STEP INSPECTION ACTION...

Page 1112: ...ner seat belt connector Is there cracking or chipping in passenger side pre tensioner seat belt connector Yes Replace wiring harness No Go to next step 3 VERIFY WHETHER MALFUNCTION IS IN PASSENGER SID...

Page 1113: ...e and passenger side air bag cut off indicator light Passenger side air bag cut off indicator light malfunction SAS unit malfunction STEP INSPECTION ACTION 1 Is vehicle equipped with passenger side ai...

Page 1114: ...asure voltage at 1U of SAS unit connector terminal Is voltage more than 9V Yes Present malfunction diagnosis Replace SAS unit See T 124 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Go to n...

Page 1115: ...tally deploy air bag modules and pre tensioner seat belts which may seriously injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components See T 117 SERVICE WARNINGS Turn...

Page 1116: ...ring harness between clock spring and SAS unit Clock spring malfunction Driver side air bag module inflator No 1 malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT DRIVER SIDE AIR BAG M...

Page 1117: ...CK SPRING REMOVAL INSTALLATION 5 INSPECT WIRING HARNESS BETWEEN CLOCK SPRING AND SAS UNIT Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Remove...

Page 1118: ...ssenger side air bag module inflator No 1 and SAS unit Passenger side air bag module inflator No 1 malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT PASSENGER SIDE AIR BAG MODULE INFLA...

Page 1119: ...on Disconnect negative battery cable and wait for more than 1 minute Connect passenger side air bag module connector Are DTCs B1913 B1925 B1933 and or B1935 indicated Yes Present malfunction diagnosis...

Page 1120: ...en driver side side air bag module and SAS unit Driver side side air bag module malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT DRIVER SIDE SIDE AIR BAG MODULE Check following PID DA...

Page 1121: ...1995 indicated Yes Present malfunction diagnosis Replace SAS unit See T 124 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed No Troubleshooting completed STEP INSPECT...

Page 1122: ...e cracking or chipping in passenger side side air bag module connector Yes Replace wiring harness No Go to next step 3 VERIFY WHETHER MALFUNCTION IS IN PASSENGER SIDE SIDE AIR BAG MODULE OR RELATED WI...

Page 1123: ...ring harness between clock spring and SAS unit Clock spring malfunction Driver side air bag module inflator No 2 malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT DRIVER SIDE AIR BAG M...

Page 1124: ...K SPRING REMOVAL INSTALLATION 5 INSPECT WIRING HARNESS BETWEEN CLOCK SPRING AND SAS UNIT Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Remove...

Page 1125: ...side air bag module inflator No 2 and SAS unit Passenger side air bag module inflator No 2 malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT PASSENGER SIDE AIR BAG MODULE INFLATOR NO...

Page 1126: ...UNIT Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Connect passenger side air bag module connector Are DTCs B2229 B2231 B2233 and or B2235 ind...

Page 1127: ...connect driver and passenger side side air bag module connectors Vehicle with side air bag Disconnect driver and passenger side curtain air bag module connectors Vehicle with curtain air bag Remove B...

Page 1128: ...inspection procedure Malfunction in wiring harness between driver side side air bag sensor and SAS unit Malfunction in driver side side air bag sensor circuit POSSIBLE CAUSE Open or short circuit in...

Page 1129: ...lower trim Disconnect driver and passenger side pre tensioner seat belt connectors Vehicle with pre tensioner seat belt Turn up floor covering Disconnect all SAS unit connectors Disconnect driver side...

Page 1130: ...ction procedure Malfunction in wiring harness between passenger side side air bag sensor and SAS unit Malfunction in passenger side side air bag sensor circuit POSSIBLE CAUSE Open or short circuit in...

Page 1131: ...trim Disconnect driver and passenger side pre tensioner seat belt connectors Vehicle with pre tensioner seat belt Turn up floor covering Disconnect all SAS unit connectors Disconnect passenger side si...

Page 1132: ...ver side curtain air bag module system circuit short to ground B2776 Driver side curtain air bag module system circuit short to power supply DETECTION CONDITION Warning Detection conditions are for un...

Page 1133: ...s of SST Fuel and thermometer checker or apply 2 ohm resistor to driver side curtain air bag module connector terminal A and B Set resistance of SST Fuel and thermometer checker to 2 ohm Connect negat...

Page 1134: ...r side curtain air bag module and SAS unit Passenger side curtain air bag module malfunction SAS unit malfunction STEP INSPECTION ACTION 1 INSPECT PASSENGER SIDE CURTAIN AIR BAG MODULE Check following...

Page 1135: ...AS UNIT Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Connect passenger side curtain air bag module connector Are DTCs B2777 B2778 B2779 and o...

Page 1136: ...t connector properly 2 INSPECT ALL SAS UNIT CONNECTORS Remove column cover Disconnect clock spring connector Remove glove compartment Disconnect passenger side air bag module connector Disconnect driv...

Page 1137: ...transaxle range switch Transaxle range switch malfunction STEP INSPECTION ACTION 1 While the vehicle is in reverse are back up lights illuminated Yes Go to next step No Repair back up light circuit t...

Page 1138: ...connector 28 pin terminal V or car navigation unit connector 16 pin terminal 2H and DSC HU CM connector 34 pin terminal AE for short to ground Is there short to ground Yes Repair wiring harness betwe...

Page 1139: ...rument cluster print plate malfunction Short to ground circuit in wiring harness between instrument cluster and SAS unit STEP INSPECTION ACTION 1 INSPECT OTHER WARNING AND INDICATOR LIGHTS CIRCUIT IN...

Page 1140: ...it connectors Connect driver and passenger side pre tensioner seat belt connectors Vehicles with pre tensioner seat belt Connect driver and passenger side curtain air bag module connectors Vehicles wi...

Page 1141: ...curtain air bag Remove B pillar lower trims Vehicle with pre tensioner seat belt Disconnect driver and passenger side pre tensioner seat belt connectors Vehicle with pre tensioner seat belt Turn up f...

Page 1142: ...s then go to Step 10 8 INSPECT WIRING HARNESS BETWEEN FUSE BLOCK AND SAS UNIT Measure voltage at terminals G JB 03 of fuse block connector Is voltage of at least either terminal more than 9 V Yes Repa...

Page 1143: ...ch to ON position Does air bag system warning light operate properly Yes Complete troubleshooting then explain repairs to customer No Recheck malfunction symptoms then repeat from Step 1 if malfunctio...

Page 1144: ...iver and passenger side pre tensioner seat belt connectors Vehicle with pre tensioner seat belt Turn up floor covering Disconnect all SAS unit connectors Is there continuity between terminal 1U of SAS...

Page 1145: ...lain repairs to customer No Recheck malfunction symptoms then repeat from Step 1 if malfunction recurs STEP INSPECTION ACTION 4 Passenger side air bag cut off indicator light is illuminated all the ti...

Page 1146: ...Vehicles with curtain air bag Connect driver and passenger side side air bag module connectors Vehicles with side air bag Connect passenger side air bag module connector Connect clock spring connecto...

Page 1147: ...N U 35 RESISTOR REMOVAL INSTALLATION U 35 RESISTOR INSPECTION U 36 POWER MOS FET REMOVAL INSTALLATION U 36 POWER MOS FET INSPECTION U 36 MAGNETIC CLUTCH DISASSEMBLY ASSEMBLY U 36 MAGNETIC CLUTCH ADJUS...

Page 1148: ...EX U 64 NO 1 INSUFFICIENT AIR OR NO AIR BLOWN FROM VENTS U 65 NO 2 AMOUNT OF AIR BLOWN FROM VENTS DOES NOT CHANGE U 65 NO 3 AMOUNT OF AIR BLOWN FROM VENTS DOES NOT CHANGE U 67 NO 4 AIR INTAKE MODE DOE...

Page 1149: ...AL INSTALLATION See U 15 AIR FILTER INSPECTION 3 A C unit See U 15 A C UNIT REMOVAL INSTALLATION See U 18 A C UNIT DISASSEMBLY ASSEMBLY 4 Rear heat duct See U 23 REAR HEAT DUCT REMOVAL INSTALLATION 5...

Page 1150: ...U 4 LOCATION INDEX End Of Sie CONTROL SYSTEM A6E850001042W01 L H D A6E8500W003 A6E8500W004...

Page 1151: ...sensor See U 39 AMBIENT TEMPERATURE SENSOR REMOVAL INSTALLATION See U 40 AMBIENT TEMPERATURE SENSOR INSPECTION 10 Cabin temperature sensor See U 40 CABIN TEMPERATURE SENSOR REMOVAL INSTALLATION See U...

Page 1152: ...U 6 LOCATION INDEX R H D A6E8500W005 A6E8500W006...

Page 1153: ...ture sensor See U 39 AMBIENT TEMPERATURE SENSOR REMOVAL INSTALLATION See U 40 AMBIENT TEMPERATURE SENSOR INSPECTION 10 Cabin temperature sensor See U 40 CABIN TEMPERATURE SENSOR REMOVAL INSTALLATION S...

Page 1154: ...ainer is highly pressurized If it is subjected to high heat it could explode scattering metal fragments and liquid refrigerant that can seriously injure you Store the refrigerant at temperatures below...

Page 1155: ...cation when charging the system with refrigerant Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts Charging Recycled R 134a Refrigerant 1 Connect an...

Page 1156: ...valve of the refrigerant tank 2 Weigh the refrigerant tank to charge the suitable amount of refrigerant Warning If the refrigerant system is charged with a large amount of refrigerant when inspecting...

Page 1157: ...h pressure side valve open is dangerous Pressure within the service cans will increase and the cans could explode scattering metal fragments and liquid refrigerant that can seriously injure you Theref...

Page 1158: ...e is no leakage after tightening the joint go to next step If there is still leakage at the same joint discharge the refrigerant and then repair the joint Repeat the charging procedure from evacuation...

Page 1159: ...engine and run it at a constant 1 500 rpm 4 Set the fan speed to MAX HI 5 Turn the A C switch on 6 Set the RECIRCULATE mode 7 Set the temperature control to MAX COLD 8 Set the VENT mode 9 Close all t...

Page 1160: ...f removal End Of Sie BLOWER UNIT DISASSEMBLY ASSEMBLY A6E851661140W02 1 Disassemble in the order indicated in the table Caution Apply only the specified grease to the link Otherwise abnormal noise or...

Page 1161: ...y cable 2 Discharge the refrigerant from the system See U 9 RECOVERY See U 9 CHARGING 3 Drain the engine coolant See E 4 ENGINE COOLANT REPLACEMENT 4 Remove the dashboard See S 82 DASHBOARD REMOVAL IN...

Page 1162: ...U 16 BASIC SYSTEM 6 Remove in the order indicated in the table Do not allow compressor oil to spill A6E8516W003 A6E8516W025 A6E8516W004 A6E8516W026...

Page 1163: ...amount of ATMOS GU10 compressor oil into the refrigerant cycle Supplemental amount approximate quantity 25 ml 25 cc 0 8 fl oz End Of Sie A6E8516W019 1 Heater hose 2 Cooler hose Lo L H D or cooler pip...

Page 1164: ...polyurethan Type C With plate and adhesive polyurethan 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly End Of Sie 9 8 7 5 4 10 19 18 17 15 16 14 13 11...

Page 1165: ...8 15 16 14 13 MANUAL AIR CONDITIONER FULL AUTO AIR CONDITIONER 3 5 5 5 36 56 31 48 N m kgf cm in lbf R R R 24 B6E8516W002 9 8 7 5 4 10 19 18 17 15 16 14 13 11 12 20 29 28 25 26 23 21 22 30 35 33 31 32...

Page 1166: ...MANUAL AIR CONDITIONER FULL AUTO AIR CONDITIONER R H D TYPE A 3 5 5 5 36 56 31 48 N m kgf cm in lbf R R B6E8516W004 9 8 7 5 4 10 19 18 17 15 16 14 13 12 20 29 28 25 26 23 21 22 30 35 33 31 32 6 1 2 34...

Page 1167: ...itioner 12 Air mix actuator full auto air conditioner 13 Air mix rod 14 Air mix crank 1 15 Air mix link 1 16 Air mix crank 2 17 Air mix link 2 manual air conditioner 18 Air mix rod holder 19 Wire clam...

Page 1168: ...the A C case apply sealant one component non solvent non alcohol type to the groove along the joint where A C case 1 and A C case 3 are joined Make sure to apply sealant completely around the whole p...

Page 1169: ...that it adheres around the hipressure side of the outlet pipe BASIC SYSTEM L H D R H D CABIN SIDE PLATE PLATE CABIN SIDE ADHESIVE POLYURETHANE 2 ADHESIVE POLYURETHANE 2 ATTACHMENT LOCATOR RIB ATTACH A...

Page 1170: ...LYURETHANE 1 ATTACHMENT LOCATOR ALIGN NOTCH WITH COVER ATTACHMENT LOCATOR ADHESIVE POLYURETHANE 1 ATTACH WITH NO GAPS B6E8516W010 4 3 1 2 3 1 2 L H D TYPE C R H D TYPE C ADHESIVE POLYURETHANE 1 TRIANG...

Page 1171: ...STALLATION 5 Remove the duct 1 6 Remove the air mix actuator Full auto air conditioner 7 Remove the adhesive polyurethane 1 See U 20 2 Adhesive polyurethane 1 Assembly Note 8 Remove the screws and cov...

Page 1172: ...DUCT 1 COVER SHIFT EXPANSION VALVE R R ADHESIVE POLYURETHANE 1 ADHESIVE POLYURETHANE 1 B6E8516W014 L H D TYPE C R H D TYPE C N m kgf cm in lbf R 3 5 5 5 36 56 31 48 OUTLET PIPE DUCT 1 PLATE SHIFT EXPA...

Page 1173: ...M PERFORMANCE TEST End Of Sie EVAPORATOR INSPECTION A6E851661810W01 1 Remove the A C unit See U 15 A C UNIT REMOVAL INSTALLATION 2 Remove the evaporator from the A C unit 3 Inspect for cracks damage a...

Page 1174: ...Discharge the refrigerant from the system See U 9 RECOVERY See U 9 CHARGING 3 Remove the right side splash shield and mudguard L H D only 4 Loosen the drive belt and remove it Caution If moisture or...

Page 1175: ...ycle 4 Remove in the order indicated in the table Do not allow compressor oil to spill 5 Install in the reverse order of removal 6 Perform the refrigerant system performance test See U 13 REFRIGERANT...

Page 1176: ...canister 6 Remove the No 3 engine mount L H D only 7 Remove the shroud panel See S 119 SHROUD PANEL REMOVAL INSTALLATION 8 Remove the right splash shield 9 Remove the right mud guard L H D only Cautio...

Page 1177: ...U 26 BASIC SYSTEM 12 Perform the refrigerant system performance test See U 13 REFRIGERANT SYSTEM PERFORMANCE TEST A6E8516W029...

Page 1178: ...allation Note 3 Cooler pipe No 3 See U 28 Refrigerant Lines Removal Note See U 29 Refrigerant Lines Installation Note 4 Cooler pipe No 4 See U 28 Refrigerant Lines Removal Note See U 29 Refrigerant Li...

Page 1179: ...or nut Spring lock coupling type 1 Set the SST 2 While looking through the inspection hole of the SST insert the protruding part of the SST until it makes contact with the cage section 3 Use the SST t...

Page 1180: ...f joint by hand 2 Tighten the joint to the specified torque If it is a nut joint tighten the nut with a spanner and torque wrench 3 Connect the block joint type pipes by grasping the female side of th...

Page 1181: ...the reverse order of removal End Of Sie AIR INTAKE ACTUATOR INSPECTION A6E854061060W02 1 Connect battery positive voltage to terminal D or F and ground to terminal F or D of the air intake actuator 2...

Page 1182: ...egative battery cable 2 Remove the glove compartment 3 Remove the car navigation unit See T 98 CAR NAVIGATION UNIT REMOVAL INSTALLATION 4 Remove in the order indicated in the table 5 Install in the re...

Page 1183: ...r 2 Verify that the air mix actuator operates as shown below If not as specified replace the air mix actuator 3 Verify that the resistance between the terminals of the air mix actuator are as shown in...

Page 1184: ...ative battery cable 2 Remove the glove compartment 3 Remove the car navigation unit See T 98 CAR NAVIGATION UNIT REMOVAL INSTALLATION 4 Remove in the order indicated in the table 5 Install in the reve...

Page 1185: ...that the airflow mode actuator operates as shown below If not as specified replace the airflow mode actuator 3 Verify that the resistance between the terminals of the airflow mode actuator is as shown...

Page 1186: ...rminal B of the blower motor and verify its operation If not as specified replace the blower motor End Of Sie RESISTOR REMOVAL INSTALLATION A6E854061215W01 1 Disconnect the negative battery cable 2 Re...

Page 1187: ...e order indicated in the table 2 Assemble in the reverse order of disassembly 3 Adjust the magnetic clutch clearance See U 38 MAGNETIC CLUTCH ADJUSTMENT Terminal Resistance ohm A D 0 21 0 23 A B 0 60...

Page 1188: ...Installation Note 1 Apply approximately 1 g 0 04 oz of silicone Shin Etsu Silicone KE 347W or similar to the contact surface of the thermal protector then thoroughly install it onto the A C compresso...

Page 1189: ...n remove the pressure plate and adjust the clearance by changing the shim 0 2 mm 0 008 in 0 5 mm 0 02 in or the number of shims Clearance 0 3 0 5 mm 0 012 0 019 in End Of Sie MAGNETIC CLUTCH INSPECTIO...

Page 1190: ...stance of approximately 100 mm 3 94 in 2 Connect positive lead to terminal A and negative lead to terminal B of the solar radiation sensor If the output voltage is not above 0 45 V replace the solar r...

Page 1191: ...is not as shown in the graph replace the ambient temperature sensor End Of Sie CABIN TEMPERATURE SENSOR REMOVAL INSTALLATION A6E854061757W01 1 Disconnect the negative battery cable 2 Remove the lower...

Page 1192: ...C unit See U 18 A C UNIT DISASSEMBLY ASSEMBLY End Of Sie EVAPORATOR TEMPERATURE SENSOR INSPECTION A6E854061022W02 1 Turn the AUTO switch on 2 Set the temperature control at MAX COLD Turn the left 3 T...

Page 1193: ...in the graph replace the water temperature sensor End Of Sie REFRIGERANT PRESSURE SWITCH REMOVAL INSTALLATION A6E854061503W01 1 Remove the battery 2 Discharge the refrigerant from the system See U 9 R...

Page 1194: ...he refrigerant pressure switch connector 3 Verify the high pressure side reading of the SST manifold gauge and continuity between the terminals of the refrigerant pressure switch If not as specified r...

Page 1195: ...r conditioner 3 Remove the center panel See T 96 CENTER PANEL MODULE REMOVAL INSTALLATION 4 Remove the screws and climate control unit Full auto air conditioner 5 Release the hook and pull the climate...

Page 1196: ...Adjust the climate control unit wires Manual air conditioner See U 46 CLIMATE CONTROL UNIT WIRE ADJUSTMENT 6 Connect the negative battery cable End Of Sie CLIMATE CONTROL UNIT DISASSEMBLY ASSEMBLY A6E...

Page 1197: ...Air Mix Wire 1 Set the temperature control dial at max cold 2 Set the air mix link to max cold in the direction shown by the arrow and insert a screwdriver at the set hole 3 Connect the air mix wire...

Page 1198: ...ition Voltage V Action 1A Blower motor feedback signal Blower motor Power MOS FET Fan switch is OFF 12 1 Inspect for continuity or short circuit Climate control unit blower motor 1A B Climate control...

Page 1199: ...control unit 2H 2L 1G 1H 1I GND Cabin temperature sensor Evaporator temperature sensor Ambient temperature sensor Water temperature sensor Air mix actuator Airflow mode actuator Under any condition B...

Page 1200: ...nding sensor See Figure 1 Inspect for continuity Climate control unit evaporator temperature sensor 1Q A 1I B Inspect for short circuit Climate control unit evaporator temperature sensor 1Q A Inspect...

Page 1201: ...w 1 0 Inspect for short circuit Climate control unit TNS relay 2B D Inspect TNS relay Inspect headlight switch Headlight switch ON 12 Inspect for continuity or short circuit Climate control unit TNS r...

Page 1202: ...oving to RECIRCULATE 12 Inspect for continuity or short circuit Climate control unit air intake actuator 2I F 2K D Inspect air intake actuator Moving to FRESH Below 1 0 2J 2K Motor drive signal Air in...

Page 1203: ...ls using an ohmmeter If not as specified replace the fan switch End Of Sie DEFROSTER SWITCH INSPECTION A6E854061050W02 1 Remove the climate control unit 2 Inspect for continuity between the defroster...

Page 1204: ...ic trouble code is indicated refer to the following diagnostic trouble code table and inspect the appropriate system Past Failure Indication Mode While in present failure indication mode press the A C...

Page 1205: ...aporator temperature sensor past 12 Ambient temperature sensor present 13 Ambient temperature sensor past 14 Water temperature sensor present 15 Water temperature sensor past 18 Air mix actuator poten...

Page 1206: ...hart If not as specified inspect the malfunctioning system Note If the AUTO switch is pressed again the on board diagnostic function will return to present failure indication mode 7 Turn the ignition...

Page 1207: ...t circuit between solar radiation sensor and climate control unit STEP INSPECTION ACTION 1 Inspect solar radiation sensor Is it okay Yes Go to next step No Replace solar radiation sensor 2 Disconnect...

Page 1208: ...ss No Go to next step 3 Is there short circuit to ground between terminal 1M of climate control unit connector 24 pin and B of cabin temperature sensor connector Yes Repair wiring harness No Connect c...

Page 1209: ...ient temperature sensor malfunction Climate control unit malfunction Open or short circuit between ambient temperature sensor and climate control unit STEP INSPECTION ACTION 1 Is resistance between te...

Page 1210: ...short circuit between water temperature sensor and climate control unit STEP INSPECTION ACTION 1 Is water temperature sensor normal Yes Go to next step No Replace water temperature sensor 2 Disconnec...

Page 1211: ...or Is there open circuit between following terminals of climate control unit connector 24 pin and air mix actuator connector 1B B 1U C 1I A Yes Repair wiring harness No Go to next step 3 Is there shor...

Page 1212: ...memory DTC 58 Air mix actuator motor lock system inspection POSSIBLE CAUSE Air mix actuator malfunction A C unit air mix link and or air mix crank malfunction Climate control unit malfunction Open or...

Page 1213: ...ctuator Short circuit between climate control unit and airflow mode actuator Open circuit between climate control unit and solar radiation sensor Open circuit between climate control unit and air mix...

Page 1214: ...s normal at present Erase the past failure from memory DTC 19 22 Climate control unit 5V power supply inspection POSSIBLE CAUSE Climate control unit malfunction Short circuit between climate control u...

Page 1215: ...of air blown from vents does not change Manual air conditioner Malfunction in blower system 4 Air intake mode does not change Air intake mode does not change when switching REC FRESH mode 5 No tempera...

Page 1216: ...step No Inspect vent for clogging then go to Step 8 5 INSPECT DEFROSTER MODE Does air blow out when in DEFROSTER mode Yes Operation is okay Recheck malfunction symptoms No Go to next step 6 INSPECT V...

Page 1217: ...gnal Is voltage approximately 12 V Yes Repair wiring harness between blower relay and blower motor then go to Step 15 No Replace blower relay then go to Step 15 8 INSPECT TO SEE WHETHER MALFUNCTION IS...

Page 1218: ...GROUND BETWEEN POWER MOS FET AND CLIMATE CONTROL UNIT Inspect for continuity at the following terminal between power MOS FET and ground Terminal B blower motor control signal ground Is there continuit...

Page 1219: ...P INSPECTION ACTION 4 Air intake mode does not change DESCRIPTION Air intake mode does not change when switching REC FRESH mode POSSIBLE CAUSE Malfunction in air intake actuator Steps 1 6 Malfunction...

Page 1220: ...n Inspect for continuity at the following terminals between climate control unit and ground Terminal 2K 12 pin FRESH motor drive signal Terminal 2I 12 pin RECIRCULATE motor drive signal Is there conti...

Page 1221: ...CORRECTLY IF AVAILABLE Is air mix wire securely installed in the correct position in relation to A C unit air mix links Yes Go to next step No Adjust air mix wire or install securely in correct positi...

Page 1222: ...climate control unit connector 12 pin Turn ignition switch to ON position Test voltage at climate control unit connector terminal F B signal Is voltage approximately 12 V Yes Go to next step No Repai...

Page 1223: ...IT AIR INTAKE DOOR Is there any foreign material or obstruction in blower unit air intake door Yes Remove obstruction then go to Step 14 No Go to next step 13 VERIFY THAT BLOWER UNIT AIR INTAKE DOOR I...

Page 1224: ...eplace condenser and vacuum refrigerant line more than 30 minutes by vacuum pump add refrigerant to specified level then go to Step 20 Since water has intermixed in receiver drier and it is saturated...

Page 1225: ...A C compressor then go to Step 20 Cause is defective A C compressor 17 CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR ELSEWHERE Is only refrigerant low pressure value high Yes Go to Step 19...

Page 1226: ...edure No Go to next step 4 INSPECT TO SEE WHETHER MALFUNCTION IS IN CLIMATE CONTROL UNIT OR ELSEWHERE Does cool air blow out when terminal 1P of climate control unit connector 24 pin A C signal is gro...

Page 1227: ...se burns out immediately go to next step 14 INSPECT WIRING HARNESS BETWEEN FUSE BLOCK AND A C RELAY FOR LACK OF CONTINUITY Test voltages at following terminals of A C relay Terminal A A C relay contro...

Page 1228: ...onnections free of oil grime Visual inspection Are piping connections free of gas leakage Are piping installation points on condenser free of gas leakage Are piping installation points on receiver dri...

Page 1229: ...DRIVE BELT Inspect drive belt See B 3 DRIVE BELT INSPECTION Is it okay Yes Go to next step No Adjust or replace drive belt then go to Step 19 16 INSPECT DRIVE BELT CONDITION Is drive belt worn Does i...

Page 1230: ...YSTEM TD 3 FUEL AND EMISSION CONTROL SYSTEMS TD 3 ENGINE ELECTRICAL SYSTEM TD 4 CLUTCH TD 5 MANUAL TRANSAXLE TD 5 AUTOMATIC TRANSAXLE TD 5 FRONT AND REAR AXLE TD 6 STEERING SYSTEM TD 6 BRAKING SYSTEM...

Page 1231: ...58 300 rpm 1 000 10 197 145 00 290 rpm Maximum difference between cylinders 196 1 2 0 28 Cylinder head bolt length mm in Standard 149 0 150 0 5 86 5 90 Minimum 150 5 5 92 Pushing distance of the front...

Page 1232: ...LF ATX LF MTX L3 Idle speed rpm 650 750 700 50 650 750 700 50 600 700 650 50 600 700 650 50 Ignition timing BTDC rpm Approx 10 700 Approx 10 700 Approx 10 650 Approx 10 650 Idle up speed E L ON 650 7...

Page 1233: ...tery type 46B24LS 36 135 50D20L 48 150 75D26L 52 195 80D26L 55 195 Slow charge A Battery type 5 hour rate 46B24LS 36 3 5 4 5 50D20L 48 4 0 5 0 75D26L 52 5 0 6 0 80D26L 55 5 5 6 5 Quick charge Battery...

Page 1234: ...xle oil Grade API service GL 4 or GL 5 Viscosity All season SAE 75W 90 Above 10 C 50 F SAE 80W 90 Capacity L US qt lmp qt 2 87 3 03 2 53 Item Specification Transaxle type FN4A EL ATF Type ATF M V Line...

Page 1235: ...F 676 6 686 6 26 64 27 03 L3 Right side 631 2 641 2 24 86 25 24 628 6 638 6 24 75 25 14 Item Specification ENGINE SPEED SENSING POWER STEERING Steering wheel Play mm in 0 30 0 1 18 Effort N m kgf cm i...

Page 1236: ...Switching point kPa kgf cm2 psi 2 450 25 355 200 2 29 Rear wheel pressure when master cylinder pressure is 5 880 kPa 60 kgf cm2 853 psi 3 480 35 5 505 300 3 44 kPa kgf cm2 psi Front disc brake Minimum...

Page 1237: ...in Tire 2 4 0 08 0 16 Rim inner 1 3 0 04 0 12 degree 0 11 0 22 Caster angle 2 Reference value normal 3 37 1 3 39 1 3 41 1 3 44 1 3 47 1 height up 3 3 32 1 3 34 1 3 36 1 3 39 1 3 42 1 Camber angle 2 Re...

Page 1238: ...2 2 32 220 2 2 32 Full load 240 2 4 35 240 2 4 35 Rear Up to 4 persons 220 2 2 32 220 2 2 32 Full load 300 3 1 44 270 2 8 39 270 2 8 39 Remaining tread mm in 1 6 0 06 1 6 0 06 Wheel and tire Wheel an...

Page 1239: ...ght 21 1 License plate light 5 2 High mount brake light 4SD In vehicle type 18 4 1 Rear spoiler type 4 1 5HB 21 1 Interior light bulb capacity W Front map light 5 2 Rear map light 5 2 Trunk compartmen...

Page 1240: ...COOLING SYSTEM ST 2 FUEL AND EMISSION CONTROL SYSTEMS ST 3 CLUTCH ST 3 MANUAL TRANSAXLE ST 3 AUTOMATIC TRANSAXLE ST 4 FRONT AND REAR AXLE ST 4 STEERING SYSTEM ST 6 BRAKING SYSTEM ST 7 SUSPENSION ST 8...

Page 1241: ...SYSTEM A6E941001001W03 SPECIAL TOOLS 1 49 JE01 061 2 303 507 Peg 49 L017 5A0 Support hanger set 49 G017 5A0 Engine support set 1 49 G032 354 2 Adjusting wrench 1 49 JE01 061 2 303 507 Peg 1 49 UN20 50...

Page 1242: ...TRANSAXLE A6E941001024W02 End Of Sie 49 B019 901B Oil Pressure Gauge 49 N013 101A Body 49 N013 102A Adapter Hose 49 L018 001 O2 sensor wrench 49 T042 001 Union wrench WDS 49 0259 770B Flare Nut Wrench...

Page 1243: ...staller WDS 49 E017 5A0 Engine Support Set 49 E011 1A0 Ring Gear Brake Set 49 0259 770B Flare Nut Wrench 49 T028 3A0 Ball joint puller set 49 G030 455 Diff side gear holder 49 G033 105 Attachment 49 F...

Page 1244: ...or rotor installer 49 H027 002 Bearing remover 49 W034 301 Support block 49 S231 626 Support block 49 B014 001 Oil seal installer 49 B025 004 Dust seal installer 49 F027 005 Attachment 62 49 W027 003...

Page 1245: ...23 Rod seal remover body 49 N032 319A Support plate 49 B032 326 Outer box protector 49 T028 301 Support plate 49 B032 324 Rod seal protector body 49 B032 325 Rod seal guide 49 B032 331 Oil seal instal...

Page 1246: ...nut wrench 49 G066 001 Adapter harness 49 U043 0A0A Oil pressure gauge set 49 C066 001 Adapter harness 49 0221 600C Disc brake expand tool 49 FA18 602 Disc brake piston wrench 49 G043 001 Adjust gaug...

Page 1247: ...A0 Ball joint puller set 49 T034 202A Guide 49 B034 216 Installer 49 S120 620 Bearing installer 49 T034 203 Attachment 49 G030 797 Handle 49 U034 204 Dust boot installer 49 U027 005 Bearing installer...

Page 1248: ...038W01 End Of Sie 49 H066 002 Deployment tool 49 D066 002 Adapter harness 49 G066 003 Adapter harness 49 L066 002 Adapter harness 49 N088 0A0 Fuel and Thermometer checker WDS 49 C061 0A0B Gas Charge S...

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Mazda 6 2002, Workshop Manual

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