Mazda 626 Station Wagon Workshop Manual Download Page 184

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CONTROL SYSTEM

ECT sensor

Accelerator position sensor

Idle switch_____________

IAT sensor No.1

IAT sensor No.2

Pump speed sensor

TDC sensor

Fuel temperature sensor

Boost sensor

Clutch switch___________

EGR valve position sensor

Injection pump EPROM

Battery

DLC

TCV

EGR solenoid valve (Vent)

EGR solenoid valve (Vacuum)

Spill valve relay

PCM control relay

FSO solenoid relay

Glow plug relay

A/C relay

Condenser fan relay

Cooling fan relay

IDM

PCM

R.H.D.

L.H.D.

Clutch pedal

Accelerator pedal

F 2-8

Summary of Contents for 626 Station Wagon

Page 1: ...Mazda Station Wagon Workshop Manual Supplement JM Z G F 1 JMZ G W 1 JM Z G W 6 w v 9 1999 1671 1E 99I European L H D U K specs ...

Page 2: ...e 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 Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized The contents of this manual including drawings and specifications are the latest avai...

Page 3: ...this manual without obligation or advance 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 information storage and retrieval system without permission in writing Mazda Motor Corporation HIROSHIMA JAPAN APPLICATION This manual is applicable to vehicles beginn...

Page 4: ...S50 400001 JMZ GF14S5Y 400001 JMZ GF14S20 400001 JMZ GF14S2Y 400001 JMZ GF14T2Y 400001 JMZ GF14R2Y 400001 JMZ GF14T20 400001 JMZ GF14R20 400001 JMZ GF14R20 400001 JMZ GF12S 0 400001 JMZ GW19F20 200001 JMZ GW19S20 200001 JMZ GW19R20 200001 JMZ GW19P20 200001 JMZ GW19P2Y 200001 JMZ GW69P2Y 200001 JMZ GW69P20 200001 JMZ GW19F50 200001 JMZ GW19F5Y 200001 JMZ GW69F5Y 200001 JMZ GW69F50 200001 JMZ GW19F...

Page 5: ...m Europe L H D 5468 1 99l 626 626 Station Wagon Wiring Diagram U K 5469 1 991 Engine Workshop Manual FP FS 1579 10 98D Engine Workshop Manual RF Turbo 1615 10 98D Manual Transaxle Workshop Manual G25M R 1441 10 94F ATX Workshop Manual GF4A EL 1414 10 931 ATX Workshop Manual GF4A EL 1393 10 93H ATX Workshop Manual FN4A EL 1623 10 98E 626 Bodyshop Manual 3310 10 97D 626 Station Wagon Bodyshop Manual...

Page 6: ... TO USE THIS M AN U A L G I 2 RANGE OF TOPICS G I 2 TROUBLESHOOTING PROCEDURE G I 2 ELECTRICAL SYSTEM G I 8 PRECAUTIONS BEFORE WELDING G I 8 ABBREVIATIONS G I 8 SCHEDULED MAINTENANCE G I 9 SCHEDULED MAINTENANCE TABLE G I 9 GI 1 ...

Page 7: ...are important hints for repairing malfunctions that are difficult to simulate Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction The on board diagnostic function is used during inspection When a DTC is shown specifying the cause of a malfunction continue the diagnostic inspection according to the items indicated by the on board diagnostic function Dia...

Page 8: ...selector lever is moved are selector lever position and indicator aligned Also when other ranges are selected from N or P during idling does vehicle creep within 1 to 2 seconds Inspect the ATF color condition Are ATF color and odor normal 1 Perform line pressure test See K 2 Line Pressure Test 1 Is line pressure okay 1 Perform stall test See K 2 Stail Speed Test 1 Is stall speed is okay Yes No Yes...

Page 9: ... order of troubleshooting H A R N E SS SIDE CONNECTOR V1EW FH0M TERMINAL SI DE H A R N E SS SID E CONNECTOR M E W FROM H A R N E SS S ID P INSPECTION describes the method to quickly determine the failed part s 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 FRAME DATA on repair order then go to next steD 2...

Page 10: ... and or after start See F2 9 NO 4 HARO START LONG CRANK ERRATIC CRANK 5 Cranks normally but will not star Starter cranks engine at normal speed but engine will not run See F2 11 NO 5 ENG1NE S TALLS AFTER START AT IDLE 6 Slow return lo Idle Engine takes more time than normal lo relurn to Idle speed See F2 15 NO 6 CRANKS NORMALLY BUT WILL NOT START 7 Engine runs rough rotiing idle Engine speed fluct...

Page 11: ...the relation between symptom and cause of the malfunction also specifies the area of the common cause when multiple malfunction symptoms occur The appropriate diagnostic inspection relating to malfunction cause as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart 2 PARTS WHICH MAY BE THE CAUSE OF PROBLEMS QUICK DIAGNOSIS CHART GI 6 ...

Page 12: ...ps make sure that Automatic Transaxle On board Diagnostic and Automatic Transaxle Basic Inspection are conducted STEP INSPECTION ACTION ACTION Is fine pressure okay Yes Go to next step __ describes the No Repair or replace any defective parts according to inspection results appropriate action to take 2 Is shift point okay Yes Go to next step as a result See K 5 Road Test Preparation No Go to sympt...

Page 13: ...ransaxle fluid ATX Automatic transaxle BBDC Before bottom dead center BTDC Before top dead center CM Control module C P U Central processing unit D E F Defroster DOHC Double over head camshaft Dl Distributor ignition D T C Diagnostic trouble code E B D Electronic Brakeforce Distribution EX Exhaust HI High HU ABS hydraulic unit IG Ignition IN Intake LED Light emitting diode L H D Left hand drive M ...

Page 14: ...riving for long period in cold temperatures or driving regularly at short distance only 4 If the vehicle is operated in very dusty or sandy areas inspect and if necessary clean or replace the air cleaner element more often than the recommended intervals 5 This is a full function check of electrical systems such as lights wiper and washer systems including wiper blades and power windows 6 If the br...

Page 15: ...ls I I I I I I I I I I I 1 Clutch fluid I I I I I I I I I I I 1 Brake lines hoses connections I I I I I I I I I I I 1 Brake fluid 6 I I I R I R I R I R Parking brake I I I I I I I I I I I 1 Power brake unit hoses I I I I I I I I I I I 1 Disc brakes I I I I I I I I I I I 1 Drum brakes I I I I I I I I I I I 1 Power steering fluid lines I I I I I I I I I I I Steering operation gear housing I I I I I ...

Page 16: ... damage carbon high tension lead condition and mea sure plug gap Replace spark plugs EMISSION CONTROL SYSTEM FOR GASOLINE Evaporative system Check system operation See W M vapor lines vacuum fitting hoses and connection Throttle positioner system if equipped Check the diaphragm and system operation vacuum fitting hoses and connection Dash pot for carburetor Check system operation E G R system Chec...

Page 17: ... transaxle oil Automatic transaxle oil level Check oil level Automatic transmission transaxle fluid level Check fluid level Automatic transmission transaxle fluid Replace automatic transmission transaxle fluid Front rear differential oil Check oil level and inspect for leakage Replace front rear differential oil Rear differential oil Check oil level and inspect for leakage Replace rear differentia...

Page 18: ...ompressor operation Check compressor operation and inspect for noise oil leakage cracks and refrigerant leakage Cabin air filter Replace cabin air filter 4WS SYSTEM Front rear power steering system hoses Check lines for improper attachment leaks cracks damage loose con nections chafing and deterioration 4WS operation linkages Inspect for leakage cracks damage and looseness Rear wheel steering angl...

Page 19: ...ENGINE FP FS FS Hi power Q FEATURES O U T L IN E B1 2 OUTLINE OF CONSTRUCTION B1 2 FEATURES B1 2 SPECIFICATIONS B1 2 ENGINE MECHANISM B1 3 CYLINDER HEAD B1 3 B1 1 ...

Page 20: ...to ATDC 6 FP The compression ratio has been increased from 9 6 1 to 9 7 1 FP SPECIFICATIONS Item Specification FP FS FS Hi power Type Gasoline 4 cycle Cylinder arrangement and number In line 4 cylinder Combustion chamber Pentroof Valve system DOHC timing belt driven 16 valves Displacement ml cc cu in 1 840 1 840 112 2 1 991 1 991 121 5 Bore x stroke mm in 83 0 x 85 0 3 27x3 35 83 0x92 0 3 27 x 3 6...

Page 21: ...ECHANISM ENGINE MECHANISM CYLINDER HEAD FP The intake port has been enlarged to improve charging efficiency This improves combustion efficiency at all speeds 1 Face lifted model 2 Current model Intake port B1 3 ...

Page 22: ...DTC P0113 F1 47 DTCP0117 F1 49 DTC P0118 F1 51 DTC P0122 F1 53 DTC P0123 F1 55 DTC P0134 F1 57 DTC P0135 F1 59 DTC P0328 F1 61 F1 1 DTC P0335 F1 62 DTC P0443 F1 64 DTC P1170 F1 66 DTC P1250 F1 68 DTC P1345 F1 70 DTC P1496 F1 72 DTC P1497 F1 74 DTC P1498 F1 76 DTC P1499 F1 78 DTC P1504 F1 80 DTC P1562 F1 82 DTC P1602 F1 84 DTC P1603 F1 87 DTC P1604 F1 87 DTC P1608 F1 88 DTC P1621 F1 89 DTC P1622 F1...

Page 23: ...ERNS ENGINE F1 138 N0 22 A C DOES NOT WORK SUFFICIENTLY F1 139 NO 23 A C ALWAYS ON OR A C COMPRESSOR RUNS CONTINUOUSLY F1 139 NO 24 A C DOES NOT CUT OFF LINDER WIDE OPEN THROTTLE CONDITIONS F1 140 N0 25 EXHAUST SULPHUR SM ELL F1 141 N0 26 INTERMITTENT CONCERNS F1 142 N0 27 CONSTANT VOLTAGE F1 142 N0 28 SPARK PLUG CONDITION F1 144 ENGINE SYSTEM INSPECTION F1 149 F1 2 ...

Page 24: ...lay and the main relay have been changed to in the relay box Improved reliability The engine control PCM program has been changed Except for GF4A EL models SPECIFICATIONS Item Engine FP FS FS Hi power Air cleaner element Type Paper element oil permeated IACvalve Type Duty control Fuel injector Type Hi ohmic Type of fuel delivery Top feed Type of drive Voltage Pressure regulator Regulating pressure...

Page 25: ...CONTROL SYSTEM WIRING DIAGRAM With Immobilizer System OUTLINE F1 4 ...

Page 26: ... OUTLINE o frxJ 8Y Ywy8QM57 M M fa fel fa Hi oX jaoiX75X 5K 0 XK CaX Ky X I XOM X7X XeXsKOfc A o V Sj 0 Esa T O o I S n a w e l Kc X a if eeüei MofcJWttW Ui h V r 1 S F1 5 ...

Page 27: ...igerant pressure switch low pressure Refrigerant pressure switch high pressure A C relay A C compressor_____________________ 31 Fan relay No 2 32 Cooling fan motor 33 Fan relay No 1 34 Condenser fan motor 35 Ignition coil 36 ABS TCS HU CU 37 Condenser 38 Purge solenoid valve 39 PRC solenoid valve 40 Magnetic clutch 41 EGR valve 42 VSS 43 Knock sensor 44 Input turbine speed sensor 45 CMP sensor 46 ...

Page 28: ...OUTLINE Without Immobilizer System HgaaaaBBESiBBBMEgKBMi _GL I I ppsqrs rT ojo rc O s OFF ACQON ST 0 9 0 ACC IÛ1 6 Ò o I a2 ST _ L c æ m Æ r i aioioio tM J e e m h ILis I Ü I y L 3 F1 7 ...

Page 29: ...8 l d i j I R W T n l æ oxk i iô f oii I j2 t in t im i SO S 2 2 a O isr O C p flin trai p 4t wH t ô fäT X t jj ÏË E 0 0 O 3Nnino ...

Page 30: ...28 Refrigerant pressure switch high pressure 29 A C relay 30 A C compressor 31 Fan relay No 2 32 Cooling fan motor 33 Fan relay No 1 34 Condenser fan motor 35 Ignition coil 36 ABS TCS HU CU 37 Condenser 38 Purge solenoid valve 39 PRC solenoid valve 40 Magnetic clutch 41 EGR valve 42 VSS 43 Knock sensor 44 Input turbine speed sensor 45 CMP sensor 46 CKP sensor 47 Fuel injector No 1 48 Fuel injector...

Page 31: ...ng Idle speed has been changed to match vehicle characteristics High vehicle speed fuel reduce corrections of fuel injection control and electronic spark advance ESA control have been eliminated Operation conditions of pressure regulator control PRC 02S heater control EGR control and A C cut off control have been modified to match vehicle characteristics Shapes and terminal numbers of PCM have bee...

Page 32: ... X X X X X X X X 1 Knock sensor X H02S X X X VSS X X X X X X o t Í Neutral clutch switch 1 X X X X X X X 3 a g TR switch 2 X X X X X X X PSP switch X X X X Brake switch X X A C switch refrigerant pressure switch X X X X X X high low pressure Generator terminal P output voltage X X X DLC terminal TEN X X X X Battery X X X X X Immobilizer unit 3 X IACvalve X Fuel injector X X Fuel pump relay X PRC s...

Page 33: ... condition The PCM carries out the PRC when all of the following conditions are satisfied At start and 104 seconds after start Intake air temperature is above 35 C 95 F Engine coolant temperature is above 90 C 194 F Throttle valve is fully closed and engine speed is below 1500 rpm No load ATX in P or N position MTX in neutral position or clutch pedal is depressed Operation condition The PCM cuts o...

Page 34: ...ntially carried over from the MPV LW FS engine models except for the operation condition and the PCM terminals connected to the fan relay System diagram With A C 1 TP sensor 2 ECT sensor 3 A C switch 4 DLC TEN terminal 5 PCM 6 Fan relay No 2 7 Cooling fan motor 8 Fan relay No 1 9 Condenser fan motor F1 13 ...

Page 35: ...r approx 4 0 seconds Startability improvement Vehicle start off for ATX For approx 2 0 seconds Acceleration perfomance improvement Throttle valve is opened above 87 5 For approx 5 0 seconds Engine reliability improvement Engine coolant temperature is above 113 C 235 F Alternates between 10 seconds on and off untill engine coolant temperature falls to 107 C 225 F Engine coolant temperature is above...

Page 36: ...rmines that IAT circuit has malfunction Sets intake air temperature for engine control 20 C 68 F Illuminates generator warning light Stops fuel cut off at shifting ATX X P0113 PCM monitors input voltage from IAT sensor when engine is running If input voltage at PCM terminal 39 is above 4 6 V PCM determines that IAT circuit has malfunction X P0117 ECT sensor PCM monitors input voltage from ECT sens...

Page 37: ...s not receive input voltage from CKP sensor for 4 2 seconds while MAF is 1 99 g sec 0 257 lb min or above PCM determines that CKP sensor has malfunction Stops fuel injection control X P0443 Purge solenoid valve PCM monitors input voltage from purge solenoid valve just after turning ignition key to ON If voltage at PCM terminal 67 is low PCM determines that purge solenoid valve circuit has malfunct...

Page 38: ...y positive terminal at PCM terminal 55 If PCM detects battery positive terminal voltage below 2 5 for 2 seconds PCM determines that back up voltage circuit has malfunction X P1602 Immobilizer system Commanded transmission from PCM to immobilizer unit exceeds limit No response from immobilizer unit X P1603 Code word is not registered in PCM X P1604 Key ID numbers are not registered in PCM X P1621 C...

Page 39: ... BRKSW Brake switch ON OFF 92 CHRGLMP Generator warning light ON OFF 42 ECT Engine coolant temperature C F 38 ECTV Engine coolant temperature signal voltage V 38 FAN2 Condenser fan control ON OFF 45 FAN3 Cooling fan control ON OFF 47 FH02S H02S V 60 FH02SH H02S heater control ON OFF 94 FP RLY Fuel pump relay control ON OFF 70 1 80 2 IACV IAC valve control ms 54 83 IAT Intake air temperature C F 39...

Page 40: ...lay No 2 ON or OFF X X 47 FPRLY Fuel pump relay ON or OFF X X 70 1 80 2 IACV IAC valve Actuated at any duty value 0 100 X X 54 83 INJ Fuel injection duration Actuated at any injection value 50 50 X 74 75 100 101 INJ 1 Fuel injector No 1 OFF X 75 INJ 2 Fuel injector No 2 OFF X 101 INJ 3 Fuel injector No 3 OFF X 74 INJ 4 Fuel injector No 4 OFF X 100 PRCV PRC solenoid valve ON or OFF X X 95 PRGV Purg...

Page 41: ...626 Workshop Manual 1577 10 97D ENGINE TUNE UP PREPARATION Except for GF4A EL Models Using the SSTs NGS tester 1 Warm up the engine to normal operating temperature 2 Shift the transaxle into neutral MTX or P N position ATX 3 Turn off all electrical loads Headlight switch Blower control switch Rear window defroster switch A C switch 4 Verify that the steering wheel is at the straight ahead position...

Page 42: ...the timing mark yellow on the crankshaft pulley is within the specification If not as specified inspect the following CMP sensor See Section F CKP sensor See Section F TP sensor See Section F ECT sensor See Section F Neutral switch MTX See Section F Clutch switch MTX See Section F TR switch ATX See K2 30 TRANSAXLE RANGE TR SWITCH INSPECTION If the devices are normal replace the PCM See Section F C...

Page 43: ... and must not be adjusted Any adjustment will negatively affect the engine performance 6 Verify that the RPM PID is within the specification If not as specified adjust the idle speed by turning the AAS Specification 500 750 rpm Caution Connecting the wrong DLC terminal may possibly cause a malfunction Carefully connect the specified terminal only 4 If using a jumper wire to turn on the test mode p...

Page 44: ...tion using the dwell tachometer If not as specified with all load conditions inspect the IAC valve If not as specified with some load condition inspect the related input switches harnesses and connectors Specification Load condition ldle up speed rpm 1 P N position Range D Noload E LON 2 600 700 P Soperating 3 650 50 A CON 4 1 Excludes temporary idle speed drop just after the electrical loads E L ...

Page 45: ... 1 7 inHg pressure to Port A Yes 7 Turn the fuel tank upside down with Port B plugged as shown in the figure 49 U014 001 PLUG 11 Apply pressure of 0 98 kPa 7 4 mmHg 0 29 InHg to Port C and inspect if there is airflow from Port A If there is no airflow replace the fuel tank FUEL PUMP RELAY REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the fuel pump relay 3 Install in the rev...

Page 46: ...wing PID value perform the following TP V PID at Constant Voltage Terminal Inspection Perform the SIMULATION TEST for the output device A C RLY FP RLY FAN2 FAN3 IACV INJ PRCV PRGV VICSV after PID DATA measurement is completed PID DATA Monitor Table Monitor item Definition Unit Condition Condition Specification Action PCM terminal 1GR 1 First gear ON OFF First gear ON Others OFF Inspect following P...

Page 47: ...ngine coolant temperature 60 C 140 F 60 C 140 F Inspect ECT sensor See Section F 38 ECTV ECT signal voltage V Engine coolant temperature 20 C 68 F 2 9 3 3 V After warm up Below 1 0 V Inspect ECT sensor See Section F 38 FAN2 Condenser fan control ON OFF Engine coolant temperature above 112 C 234 F ON Terminal TEN DLC shorted to GND and throttle valve open ON A C operating ON Others OFF Inspect foll...

Page 48: ...N 0 0 ms Idle 2 0 2 5 ms Inspect following PIDs MAF V IAT V RPM TP V ECT V NL SW FH02S PSP SW BRK SW A C SW B Inspect CMP sensor See Section F 74 75 100 101 KR Knocking retard DEG Ignition switch ON 0 DEG Idle 0 DEG Inspect knock sensor See Section F 57 LSW 1 TR switch L range ON OFF L range ON Others OFF Inspect TR switch See Section K2 30 TRANSAXLE RANGE TR SWITCH INSPECTION 7 LINE 1 Pressure co...

Page 49: ...on switch ON 0 step Idle 0 step Cranking 40 60 steps Inspect following PIDs ECT V TP V Inspect EGR valve See Section F 46 56 68 72 SHIFT A 1 Shift solenoid A Fourth gear 99 Others 0 Inspect shift solenoid A See Section K2 38 SOLENOID VALVES INSPECTION 82 SHIFT B 1 Shift solenoid B First gear 99 Others 0 Inspect shift solenoid B See Section K2 38 SOLENOID VALVES INSPECTION 99 SHIFT C 1 Shift soleno...

Page 50: ...20 km h 12 mph Vehicle speed 40 km h 25 mph 40 km h 25 mph ATX Inspect VSS See Section K2 36 VEHICLE SPEED SENSOR VSS INSPECTION MTX Inspect instrument cluster See Section T 26 INSTRUMENT CLUSTER INSPECTION 58 MAINRELAY REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the main relay 3 Install in the reverse order of removal F1 29 ...

Page 51: ...es perform the Simulation Test to identify which output devices are malfunctioning Simulation test Output devices can be turned on and off by sending simulation command signals from the NGS tester to the PCM The Idling Test and Ignition ON Test are available in this test These tests will verify the PCM status output devices and related circuit wiring harnesses Diagnostic support procedure This tes...

Page 52: ...o the vehicle PROGRAM CARD 3 Movethe cursor to VEHICLE ENGINE SELECTION 4 Press the TRIGGER key to enter this selection DIAGNOSTIC DATA LINK VIEW RECORDER AREAS DIGITAL MEASUREMENT SYSTEM NEW GENERATION STAR SETUP SELECT I TEM AND P R E S S TRIGGER TO START 5 Move the cursor to SELECT NEW VEHICLE YEAR MODEL 6 Press the TRIGGER key to enter this selection In o v e h ic l e s e l e c t e d I SELECT ...

Page 53: ...LEAR DIAGNOSTIC TEST RESULTS 19 Press the TRIGGER key to enter this selection HEAD CLEAR DIAGNOSTIC TEST RESULTS SELECT ITEM AND PRESS TRIGGER TO START 20 Press START 2 Set the select switch on the SST self diagnosis checker to A 3 Turn the dial switch on the SST system selector to 1 and the test switch to SELF TEST 4 Turn the ignition key to ON engine off 5 Verify that the buzzer sounds for appro...

Page 54: ...y Note The DTC will be output as shown EX DTC 0102 0 1 0 2 A Approx 1 2 sec r n n in B Approx 1 6 sec C Approx 0 4 sec D Approx 4 0 sec E Approx 8 0 sec TIME TO DISPLAY NEXT DTC A BC D E 7 After completion of repairs erase all DTCs from the memory See F1 36 Not using the NGS tester 8 Remove the voltmeter and jumper wire PID DATA monitor and record procedure 1 Perform the NGS tester Hook up Procedu...

Page 55: ...rform Steps 1 through 15 from the DTC Reading Procedure See F1 31 Using the NGS tester 3 Move the cursor to DIAGNOSTIC SUPPORT PROCEDURE 4 Press the TRIGGER key to enter this selection I I DIAGNOSTIC TEST MOOES PID DATA MONITOR AND RECORD SIMULATION TEST DIAGNOSTIC SUPPORT PROCEDURE DIAGNOSTIC TROUBLE CODE LIBRARY i I SELECT ITEM ANO PRESS TRI GOER TO START 5 Move the cursor to ALL TEST or SINGLE ...

Page 56: ...INJ 1 PRGV FAN3 INJ 2 SEGRP 9 Press START Note If the screen displays TEST CONDITION NOT CORRECT inspect the following three signal conditions and determine whether or not they are normal Idle SW ON Equipped vehicles TR SW P or N RPM above 550 CURRENT DATA SIMULATION DATA MA OFF INJ 1 SELECT IT E AHO PRESS TR I GGER TO START 1IGNITION ON TEST 1 IDLING TEST SELECT ITEM AND PR ESS TR IG GER TO START...

Page 57: ...NJ PRCV EGRBP INJ 1 PRGCHK CURRENT DATA SIMULATION DATA O F F ON FP RLY P R E S S TRIGGER TO START 11 To perform the simulation again press the TRIGGER key To exit the IGNITION TEST press the CANCEL key SIMULATION IS COMPLETED PRESS TRIGGER FOR PID SCREEN P R E SS CANCEL TO E X IT AFTER REPAIR PROCEDURE Except for GF4A EL Models Using the NGS tester 1 After repairs have been made perform the DTC R...

Page 58: ...C P0123 P0134 02S 11 CIRCUIT NO ACTIVITY DETECTED H02S circuit no activity detected See F1 57 DTC P0134 P0135 02S 11 HEATER CIRCUIT MALFUNCTION H02S heater circuit malfunction See F1 59 DTC P0135 P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT Knock sensor circuit high input See F1 61 DTC P0328 P0335 CRANKSHAFT POS SENSOR CKT MALFUNCTION CKP sensor circuit malfunction See F1 62 DTC P0335 P0443 EVAP SYSTEM...

Page 59: ...UCK See K2 100 DTC P0751 P0752 SHIFT SOLENOID A STUCK ON See K2 102 DTC P0752 P0753 SHIFT SOLENOID A ELECTRICAL See K2 104 DTC P0753 P0756 I SHIFT SOLENOID B PERF STUCK See K2 107 DTC P0756 P0757 SHIFT SOLENOID B STUCK ON See K2 109 DTC P0757 P0758 SHIFT SOLENOID B ELECTRICAL See K2 111 DTC P0758 P0761 SHIFT SOLENOID C PERF STUCK See K2 114 DTC P0761 P0762 SHIFT SOLENOID C STUCK ON See K2 116 DTC ...

Page 60: ...PEN OR SHORT EGR valve motor coil 4 open or short See F1 78 DTC P1499 P1504 IAC CKT MALFUNCTION IAC valve circuit malfunction See F1 80 DTC P1504 P1562 PCM BB VOLTAGE LOW Battery voltage circuit malfunction See F1 82 DTC P1562 P1602 IMMOBILIZER UNIT PCM COMM ERROR Immobilizer unit PCM communication error See F1 84 DTC P1602 P1603 ID NUMBER UNREGISTERED Key ID numbers are not registered in PCM See ...

Page 61: ...line communication error See F1 91 DTC P1627 P1631 GENERATOR NO GENERATE ELECTRICITY Generator output voltage signal no electricity See F1 93 DTC P1631 P1633 BATTERY VOLTAGE CIRCUIT MALFUNCTION Battery overcharge See F1 95 DTC PI633 P1634 GENERATOR BATTERY TERMINAL OPEN Generator terminal B circuit open See F1 97 DTC P1634 F1 40 ...

Page 62: ...TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMI...

Page 63: ...e any continuity Yes Go to next step No Repair or replace suspected harness then go to Step 8 7 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR SHORT Check continuity between following circuits MAF sensor terminal E hamess side and body ground MAF sensor connector terminals D harness side and E harness side Are there any continuity Yes Repair or replace suspected harness then go to next step No Replace MAF ...

Page 64: ...LABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT OR CONSTANT Connect NGS tester to DLC Start engine Access MAF V PID using NGS tester Is MAF ...

Page 65: ... GROUND CIRCUIT FOR OPEN Check for continuity between MAF sensor terminal D harness side and PCM terminal 36 harness side Is there any continuity Yes Replace MAF sensor then go to next step No Repair or replace suspected harness then go to next step 7 VERIFY TROUBLESHOOTING OF DTC P0103 COMPLETED Make sure to reconnect all disconnected connectors Start engine Clear DTC from memory using NGS tester...

Page 66: ...nosis according to available Service information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT OR CONSTANT Turn ignition key to ON Engine OFF Access IAT V PID using NGS tester Is IAT V PID below 0 2 V Yes Go to next step No Intermittent concern is existing Go to INTERMITTENT CONCERN TROUBLESHOOTING procedure See F1 1...

Page 67: ...sensor terminals A and B harness side Is there any continuity Yes Repair or replace harness then go to Step 7 No Go to next step 7 VERIFY TROUBLESHOOTING OF DTC P0112 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from PCM memory using NGS tester Start engine Is same DTC present Yes Replace PCM then go to next step No Go to next step 8 VERIFY AFTER REPAIR PROCEDURE Perform ...

Page 68: ...AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT OR CONSTANT Turn ignition key to ON Engine OFF Access ECT V PID using NGS tester Is ECT ...

Page 69: ...A harness side and PCM terminal 39 Is there any continuity Yes Go to next step No Repair or replace harness then go to Step 9 8 INSPECT ECT SENSOR GROUND CIRCUIT FOR OPEN Check continuity between IAT sensor terminal B harness side and PCM terminal 91 Is there any continuity Yes Go to next step No Repair or replace harness then go to next step 9 VERIFY TROUBLESHOOTING OF DTC P0113 COMPLETED Make su...

Page 70: ...ated repair information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT OR CONSTANT Turn ignition key to ON Engine OFF Access ECT V PID using NGS tester Is ECT V PID below 0 2 V Yes Go to next step No Intermittent concern is existing G...

Page 71: ...ls A and B harness side Is there any continuity Yes Repair or replace harness then go to next step No Go to next step 7 VERIFY TROUBLESHOOTING OF DTC P0117 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from PCM memory using NGS tester Turn ignition key to ON Engine OFF Is same DTC present Yes Replace PCM then go to next step No Go to next step 8 VERIFY AFTER REPAIR PROCEDU...

Page 72: ...ATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT OR CONSTANT Turn ignition key to ON Engine OFF Access ECT V PID using NGS tester I...

Page 73: ...arness side and PCM terminal 3E Is there any continuity Yes Go to next step No Repair or replace harness then go to Step 9 8 INSPECT ECT SENSOR GROUND CIRCUIT FOR OPEN Check continuity between ECT sensor terminal B harness side and PCM terminal 4F Is there any continuity Yes Go to next step No Repair or replace harness then go to next step 9 VERIFY TROUBLESHOOTING OF DTC P0118 COMPLETED Make sure ...

Page 74: ...AL SIDE PCM 11I I I I I I I I I I I I I I I I I I I I I I I I T r I I I I I r i i I I i I I I I 1 1 1 1 m ri ri r r n i 89 90 91 HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis acc...

Page 75: ... to Step 8 6 VERIFY TP SIGNAL CIRCUIT FOR OPEN Turn ignition key to OFF Disconnect PCM connector Connect breakout box with PCM disconnected Disconnect TP sensor connector Check for continuity between TP sensor terminal C harness side and breakout box terminal 89 Is there continuity Yes Go to next step No Repair or replace suspected harness then go to Step 8 7 VERIFY TP SIGNAL CIRCUIT FOR SHORT TO ...

Page 76: ...TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service 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 2 VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT ...

Page 77: ... at terminals 89 90 and 91 damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair terminal then go to Step 9 No Repair or replace open circuit in wiring harness between TP sensor terminal B and PCM connector terminal 91 harness side Then go to Step 9 8 VERIFY TP SIGNAL CIRCUIT FOR SHORT TO CONSTANT VOLTAGE CIRCUIT Check for continuity between TP sensor terminals A and C I...

Page 78: ...sis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 VERIFY CURRENT INPUT SIGNAL STATUS Warm up engine Access FH02S PID using NGS tester Verify PID while racing engine in PARK or NEUTRAL Is PID reading okay More than 0 55 V when suddenly depressing accelerator pedal rich condition Less than 0 55 V just after release of accelerator peda...

Page 79: ...lace faulty parts then go to Step 7 No Go to next step 6 INSPECT ENGINE COMPRESSION Inspect engine compression See Section B Is it okay Yes Go to next step No Implement engine overhaul for repairs then go to next step 7 VERIFY TROUBLESHOOTING OF DTC P0134 or P0154 COMPLETED Make sure to reconnect all disconnected connectors Turn ignition key to ON Engine OFF Clear DTC from memory using NGS tester ...

Page 80: ...HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE 94 HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to n...

Page 81: ...harness side and body ground Is there any continuity Yes Repair or replace harness for short to ground then go to Step 9 No Go to next step 7 INSPECT CONTROL CIRCUIT OF H02S HEATER FOR OPEN CIRCUIT Check continuity between H02S terminal D harness side and PCM terminal 94 Is there any continuity Yes Go to next step No Repair or replace harness for open circuit then go to Step 9 8 VERIFY TROUBLESHOO...

Page 82: ...available Yes Perform repair or diagnosis according to available Service information If vehicle is not repaired then go to next step No Go to next step 2 CHECK KNOCK SIGNAL CIRCUIT FOR OPEN Turn ignition key to OFF Disconnect knock sensor connector Measure voltage between knock sensor terminal and body ground Is voltage approx 5 V Yes Then go to Step 4 No Go to next step 3 CHECK PCM CONNECTOR Disc...

Page 83: ...alfunction CKP SENSOR PCM CKP SENSOR n n n HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE PCM W ï i ï i i ï ï i i J t x i i i i i i i i i i 21 T r r T T x r HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE 22 t i i í i lIi X I I I I I I I r i I I I I J Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is an...

Page 84: ...1 CKP sensor terminal B and PCM terminal 22 Then go to Step 10 8 INSPECT CKP SENSOR CIRCUIT FOR SHORT TO GROUND Disconnect CKP sensor connector Check for continuity between PCM terminal 21 harness side and body ground Is there any continuity Yes Repair or replace harness then go to Step 10 No Go to next step 9 INSPECT CKP SENSOR CIRCUIT FOR SHORT TO GROUND Disconnect CKP sensor connector Check for...

Page 85: ...HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE 67 PCM X X g m i W M i r i T n ï iV i 1 1 1 1 HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Sen ice Informat...

Page 86: ...age between purge solenoid valve connector terminal A and body ground Is voltage B Yes Go to next step No Repair or replace harness then go to Step 10 8 INSPECT POOR CONNECTION OF PCM CONNECTOR Turn ignition key to OFF Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair or replace terminal then go to Step 10 No Go to n...

Page 87: ...TINUOUS CONCERN Turn ignition key to ON Engine OFF Clear DTC from memory using NGS tester Perform following procedure twice Start engine Access ECT and RPM PIDs using NGS tester Make sure that ECT PID is above 80 C 176 F Increase and keep engine speed above 1 500 rpm for at least 20 4 seconds Is another DTC present Yes Go to appropriate DTC troubleshooting procedures No Go to next step 3 IDENTIFY ...

Page 88: ...ous Scalding coolant and steam may shoot out and cause serious injury When removing radiator cap wrap a thick cloth around and turn It slowly Remove radiator cap Implement procedure to bleed air from engine coolant then run engine at idle Is there any small bubble which makes engine coolant white at filling opening Note Large bubble are normal since they are remaining air coming out from engine co...

Page 89: ...CONNECTOR VIEW FROM TERMINAL SIDE r W i I O M l i I l t T T i l l i l I I I I H X i HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE 95 Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service information If...

Page 90: ...sure voltage between PRC solenoid valve terminal A harness side and body ground Is voltage B Yes Go to next step No Repair or replace harness then go to Step 10 8 INSPECT POOR CONNECTION OF PCM CONNECTOR Turn ignition key to OFF Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair terminal then go to Step 10 No Go to ne...

Page 91: ...y Is any related Service Information available Yes Perform repair or diagnosis according to available Sen ice Information If vehicle is not repaired then go to next step No Go to next step 2 INSPECT POOR CONNECTION OF CMP SENSOR CONNECTOR Turn ignition key to OFF Disconnect CMP sensor connector Check for poor connection damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repa...

Page 92: ...ce harness then go to Step 9 No Go to next step 8 INSPECT CKP SENSOR CIRCUIT FOR SHORT TO GROUND Disconnect CKP sensor connector Check for continuity between PCM terminal 86 harness side and body ground Is there any continuity Yes Repair or replace harness then go to next step No Go to next step 9 VERIFY TROUBLESHOOTING OF DTC P1345 COMPLETED Make sure to reconnect all disconnected connectors Clea...

Page 93: ...NESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 CLASSIFY INTERMITTENT CONCERN O...

Page 94: ... CONNECTION OF PCM CONNECTOR Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair terminal then go to Step 11 No Go to next step 9 INSPECT CONTROL CIRCUIT FOR SHORT TO GROUND Check continuity between EGR valve terminal E harness side and body ground Is there continuity Yes Repair or replace harness then go to Step 11 No...

Page 95: ... FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any Sen ice Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 CLASSIFY INTERMITTENT CONCERN OR CONTINUOUS CONCERN Tur...

Page 96: ...TION OF PCM CONNECTOR Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair terminal then go to Step 11 No Go to next step 9 INSPECT CONTROL CIRCUIT FOR SHORT TO GROUND Check continuity between EGR valve terminal A harness side and body ground Is there continuity Yes Repair or replace harness for short to ground then go ...

Page 97: ...M TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 CLASSIFY INTERMITTENT CONCERN OR CONTINUOUS CONCERN Turn ig...

Page 98: ...R CONNECTION OF PCM CONNECTOR Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Are there any malfunctions Yes Repair terminals then go to Step 11 No Go to next step 9 INSPECT CONTROL CIRCUIT FOR SHORT TO GROUND Check continuity between EGR valve terminal B harness side and body ground Is there continuity Yes Repair or replace harness then go to Step 11 ...

Page 99: ...I I II I I n I Pi I j HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 CLASSI...

Page 100: ...R CONNECTION OF PCM CONNECTOR Disconnect PCM connector Check for poor connection damaged pulled out terminals corrosion etc Are there malfunctions Yes Repair terminal then go to Step 11 No Go to next step 9 INSPECT CONTROL CIRCUIT FOR SHORT TO GROUND Check continuity between EGR valve terminal F harness side and body ground Is there any continuity Yes Repair or replace harness then go to Step 11 N...

Page 101: ...0 Open circuit between IAC valve terminal B and PCM terminal 40 Poor connection of IAC valve connector or PCM connector PCM malfunction PCM IAC VALVE IAC VALVE HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE 54 PCM r r t i th 1 T 7 M i i i r 0 i i i i i i t i i r i v r T 83 7 HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATI...

Page 102: ...uity between IAC valve terminal A harness side and body ground Is there any continuity Yes Repair or replace harness then go to Step 14 No Go to next step 8 INSPECT POWER CIRCUIT FOR OPEN Turn ignition key to OFF Check continuity between IAC valve terminal A harness side and PCM terminal 54 Is there any continuity Yes Repair or replace harness then go to Step 14 No Goto Step 14 9 INSPECT POOR CONN...

Page 103: ...CM determines that backup voltage circuit has malfunction POSSIBLE CAUSE Meltdown ROOM fuse Open circuit in wiring between battery positive terminal harness side and PCM terminal 1A harness side Poor connection of PCM connector PCM malfunction PCM ROOM FUSE 55 T T T 1 PCM I I I I I I I r I i i i i i I i x r I r r r i i i i x HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP ...

Page 104: ... to Step 6 No Go to next step 5 INSPECT MONITOR CIRCUIT FOR OPEN Disconnect battery cables Check continuity between ROOM fuse terminal and PCM terminal 55 Is there any continuity Yes Go to next step No Repair or replace harness then go to next step 6 VERIFY TROUBLESHOOTING OF DTC P1562 COMPLETED Make sure to reconnect all disconnected connectors Turn ignition key to OFF then start engine Is same D...

Page 105: ...ground circuit inwiring between immobilizer unit terminal F and coil terminal A Short to ground circuit inwiring between immobilizer unit terminal D and coil terminal C COIL IMMOBILIZER UNIT PCM G 0 COIL J HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE IMMOBILIZER UNIT A X I B D F J HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE PCM HH I I I M l I I Ì 1 1 1 1 I I I I I I 1 1 1 I I 66 HARNESS SIDE ...

Page 106: ...re there any malfunctions Yes Repair or replace harness then go to Step 19 No Go to next step 9 INSPECT COMMUNICATION UNE FOR OPEN CIRCUIT Measure continuity between immobilizer unit terminal A harness side and PCM terminal 66 Is there any continuity Yes Go to step 19 No Repair or replace harness then go to Step 19 10 CLASSIFY MALFUNCTION BY ANOTHER DETECTED DTC Has DTC P1602 been detected Yes Go ...

Page 107: ...ir or replace harness then go to Step 19 18 INSPECT COMMUNICATION LINE FOR SHORT CIRCUIT Measure resistance between immobilizer unit terminal A harness side and body ground Is there any continuity Yes Repair or replace harness then go to next step No Go to next step 19 VERIFY TROUBLESHOOTING OF DTC P1602 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS t...

Page 108: ...ROCEDURE Are any DTCs present Yes Go to applicable DTC inspection See F1 37 DTC TABLE No Troubleshooting completed DTC P1604 Except for GF4A EL Models DTC P1604 Code word is not registered in PCM DETECTION CONDITION Code word is not registered in PCM POSSIBLE CAUSE Immobilizer system reprogram procedure code word was not performed after replacing PCM Diagnostic procedure STEP INSPECTION ACTION 1 V...

Page 109: ...alve EGR valve and or VICS solenoid valve connectors Measure voltage following connectors PRC solenoid valve terminal B harness side and body ground Purge solenoid valve terminal B harness side and body ground EGR valve terminal A harness side and body ground EGR valve terminal B harness side and body ground EGR valve terminal E harness side and body ground EGR valve terminal F harness side and bo...

Page 110: ...edure See F1 36 AFTER REPAIR PROCEDURE Are any DTCs present Yes Go to applicable DTC inspection See F1 37 DTC TABLE No Troubleshooting completed DTC P1622 Except for GF4A EL Models DTC P1622 Key ID number mismatch DETECTION CONDITION ID number stored in immobilizer unit and PCM does not match This DTC is indicated only after immobilizer unit is replaced and reprogramming system POSSIBLE CAUSE Tran...

Page 111: ...tep 3 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See F1 36 AFTER REPAIR PROCEDURE Are any DTCs present Yes Go to applicable DTC inspection See F1 37 DTC TABLE No Troubleshooting completed DTC P1624 Except for GF4A EL Models DTC P1624 Immobilizer system communication counter 0 DETECTION CONDITION PCM detected immobilizer system communication malfunction more than three times POSSI...

Page 112: ...nspection See F1 37 DTC TABLE No Troubleshooting completed DTC P1627 Except for GF4A EL Models DTC P1627 PCM TCS line communication error DETECTION CONDITION No pulse signal is input to PCM or pulse shape is abnormal when vehicle is driven above 5 6 km h 3 7 mph POSSIBLE CAUSE ABS TCS HU CM malfunction Open circuit or short to GND in wiring from ABS TCS HU CM terminal L to PCM terminal 11 ABS TCS ...

Page 113: ... ON Engine OFF Measure voltage between ABS TCS HU CM terminal L and body ground Is voltage B Yes Repair or replace harness for short to ground then go to Step 8 No Go to next step 5 INSPECT COMMUNICATION LINE FOR SHORT TO GROUND Turn ignition key to OFF Check for continuity between ABS TCS HU CM terminal L and body ground Is there continuity Yes Repair or replace harness for short to ground then g...

Page 114: ...T i t i i i i i i n i i i i i j 53 HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE 97 Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No ...

Page 115: ...ness side and body ground Is there any continuity Yes Repair or replace harness then go to Step 10 r No Go to next step 8 INSPECT GENERATOR CONTROL CIRCUIT FOR OPEN Measure resistance between generator terminal D harness side and PCM terminal 53 Is there any continuity Yes Go to next step No Repair or replace harness then go to Step 10 9 INSPECT GENERATOR OUTPUT VOLTAGE MONITOR CIRCUIT FOR OPEN Me...

Page 116: ...97 Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 CLASSIFY INTERMITTENT CONCERN OR CONTINUOUS CONCERN Start engine...

Page 117: ...key to ON Engine OFF Yes Repair or replace harness then go to Step 8 Measure voltage between generator terminal D harness side and body ground Is voltage B No Go to Step 8 7 INSPECT GENERATOR CONTROL TERMINAL FOR SHORT TO POWER Measure resistance between generator terminal D part side and body ground Is voltage B Yes Repair or replace generator then go to next step No Go to next step 8 VERIFY TROU...

Page 118: ...1 1 HARNESS SIDE CONNECTOR 9 7 VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service Information available Yes Perform repair or diagnosis according to available Service Information If vehicle is not repaired then go to next step No Go to next step 2 CLASSIFY INT...

Page 119: ...NSPECT BATTERY CHARGING CIRCUIT Start engine Disconnect battery positive terminal Does engine stall Yes Repair or replace harness between generator terminal B and battery positive terminal then go to next step No Go to next step 7 VERIFY TROUBLESHOOTING OF DTC P1634 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Turn ignition key to OFF then sta...

Page 120: ...speed See F1 116 NO 6 SLOW RETURN TO IDLE 7 Engine runs rough rolling idle Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively See F1 117 NO 7 ENGINE RUNS ROUGH ROLLING IDLE 8 Fast idle runs on Engine speed continues at fast idle after warm up Engine runs after ignition switch is turned off See F1 120 NO 8 FAST IDLE RUNS ON 9 Low idle stalls during de...

Page 121: ...E COMPARTMENT 20 Engine noise Engine noise from under hood See F1 138 N0 20 ENGINE NOISE 21 Vibration concerns engine Vibration from under hood or driveline See F1 138 N0 21 VIBRATION CONCERNS ENGINE 22 A C does not work sufficiently A C compressor magnetic clutch does not engage when A C is turned on See F1 139 N0 22 A C DOES NOT WORK SUFFICIENTLY 23 A C is always ON or A C compressor runs contin...

Page 122: ...atic crank Will not crank Melts m ain or other fuse Upshift downshift engagement Acceleration cruise Acceleration cruise Acceleration cruise Acceleration Acceleration cruise deceleration Acceleration cruise Acceleration cruise Acceleration cruise After start at idle Runs cold Overheating S ee Section K1 S ee Section K2 0 Starter motor malfunction Mechanical or electrical O Starter circuit includin...

Page 123: ...e Acceleration Acceleration cruise deceleration Acceleration cruise Acceleration cruise Acceleration cruise After start at idle Runs cold Overheating S ee Section K1 See Section K2 0 Accelerator cable free play misadjustment O o 0 O O O O O 0 O 0 O O O Fuel quality O O O O O O O O O 0 O Engine overheating O O O O o o o o o 0 0 o O Air cleaner element clogging or restriction O O o o o o o o o O o o...

Page 124: ...rake switch and related circuit malfunction Upshift downshift engagement Spark plug condition Constant voltage Intermittent concerns Exhaust sulphur smell A C does not cut off under wide open throttle conditions A C always O N or A C compressor runs continuously A C does not work sufficiently Vibration concerns engine Engine noise Fuel odor i n engine compartment Exhaust smoke Runs cold Overheatin...

Page 125: ... main or other fuse Upshift downshift engagement Acceleration cruise Acceleration cruise Acceleration cru ise Acceleration Acceleration cruise deceleration Acceleration cruise Acceleration cruise Acceleration cruise After start at idle Runs cold Overheating S ee Section K1 S ee Section K2 O O Neutral or clutch switch and related circuit malfunction o O O OO O O O O O o MAF sensor and related circu...

Page 126: ...A MAIN fuse Generator IG KEY 60 A IG KEY 60 A IG KEY fuse Ignition switch INJ 30 A INJ 30 A INJ fuse Main relay Main relay PCM Fuel pump relay Fuel injectors Purge solenoid valve MAF sensor VICS solenoid valve VSS PRC solenoid valve EGR valve Fuel pump relay Fuel pump ROOM 10 A ROOM 10 A ROOM fuse PCM ENGINE 10 A ENGINE 10 A ENGINE fuse Ignition coil Condenser H02S Main relay METER 10 A METER 10 A...

Page 127: ...ectrical accessories work Yes Go to next step No Inspect charging system See Section G 5 NOTE Following test should be performed on ATX only For MTX go to next step Connect NGS tester to DLC Access TR SW PID Turn ignition switch ON Is TR SW PID indicated on when selecting P or N range Yes Go to next step No Inspect adjustment of TR switch If TR switch is adjusted properly inspect for open circuit ...

Page 128: ... and AFTER REPAIR PROCEDURE See Section F Caution Disconnecting connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector Always clean the quick release connector joint area before disconnecting connecting and make sure that It is free of foreign material Diagnostic Procedure STEP INSPECTION RESULTS ACTION 1 Inspect for follow...

Page 129: ...sure regulator 11 Disconnect vacuum hose from pressure regulator and plug hose Start engine Does fuel line pressure remain within 20 kPa 0 21 kgf cm2 3 psi while driving vehicle Yes Go to next step No Inspect for clogged fuel filter 12 Connect vacuum hose to pressure regulator Install vacuum gauge to intake manifold Start engine Does fuel pressure gauge reading increase as vacuum gauge reading dec...

Page 130: ...ite 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 See Section F Caution Disconnecting connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector Always clean the quick release connector joint area before disc...

Page 131: ...pair or replace wiring harness 10 Turn ignition switch on Access B PID Is B or VPWR PID okay B VPWR PID Battery voltage Yes Go to next step No Repair or replace wiring harness 11 Disconnect immobilizer unit connector Turn ignition switch on Is there battery voltage at immobilizer unit connector terminal J Yes Inspect for open circuit between PCM connector terminal 5 for GF4A EL models or 66 except...

Page 132: ... to next step No Replace malfunctioning parts 18 Measure gap between CKP sensor and teeth of crankshaft pulley Specification 0 5 1 5 mm 0 020 0 059 In Is gap within specifications Yes Go to next step No Adjust CKP sensor 19 Inspect for cracks on high tension leads Is there any crack on high tension leads Yes Repair suspected high tension lead No Go to next step 20 Is strong blue spark visible at e...

Page 133: ...eplace pressure regulator 26 Note The following test is for stall concerns with A C on If other symptoms exist go to next step Connect pressure gauges to A C low and high pressure side lines Turn A C on and measure low side and high side pressure See Section U Are pressures within specifications Yes Go to next step No If A C is always on go to symptom troubleshooting No 23 A C is always ON or A C ...

Page 134: ...y and damage Always keep sparks and flames away from fuel Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE See Section F Caution Disconnecting connecting the quick release connector without cleaning it may possibly cause da...

Page 135: ... B PID Is B or VPWR PID okay B VPWR PID Battery voltage Yes Go to next step No Repair or replace wiring harness 11 Disconnect immobilizer unit connector Turn ignition switch on Is there battery voltage at immobilizer unit connector terminal J Yes Inspect for open circuit between PCM connector terminal 5 for GF4A EL models 66 except for GF4A EL and immobilizer unit connector terminal A No Repair or...

Page 136: ...asure gap between CKP sensor and teeth of crankshaft pulley Specification 0 5 1 5 mm 0 020 0 059 in Is gap within specification Yes Go to next step No Adjust CKP sensor 20 Inspect for cracks on high tension leads Is there any crack on high tension leads Yes Repair suspected high tension leads No Go to next step 21 Is strong blue spark visible at each disconnected high tension lead while cranking e...

Page 137: ... replace pressure regulator 27 Disconnect vacuum hose between purge solenoid valve and intake manifold from purge solenoid valve side Plug opening end of vacuum hose Attempt to start engine Is starting condition improved Yes Inspect if purge solenoid valve is stuck open mechanically Inspect evaporative emission control system No Go to next step 28 Is air leakage felt or heard at intake air system ...

Page 138: ...rk leakage from high tension leads Purge solenoid valve malfunction Improper operation of IAC valve EGR valve malfunction Erratic or no signal from CMP sensor Low engine compression Erratic signal from CKP sensor Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connectors Inadequate fuel pressure Fuel pump body mechanical malfunc...

Page 139: ...symptom troubleshooting No 23 A C is always ON or A C compressor runs continuously For other symptoms inspect following Refrigerant charging amount Condenser fan operation 5 Note Following test is for engine running rough with P S on If other symptoms exist go to next step Start engine and run it at idle Access PSP SW PID Inspect if PSP SW PID is on while turning steering wheel right to left Is PS...

Page 140: ... okay replace pressure regulator 13 Connect NGS tester to DLC Start the engine and run it at idle Access FH02S or 02SII PID Is FH02S or 02SII PID okay More than 0 45 V when accelerator pedal is suddenly depressed rich condition Less than 0 45 V during fuel cut lean condition Yes Go to next step No Inspect and repair or replace faulty H02S harness connector or terminal then go to next step 14 Disco...

Page 141: ... higher speed Yes Repair or replace parts as necessary No Verify accelerator cable free play 4 Verify test results If okay return to diagnostic index to service any additional symptoms NO 9 LOW IDLE STALLS DURING DECELERATION 9 Low idle stalls during deceleration DESCRIPTION Engine stops unexpectedly at beginning of deceleration or recovery from deceleration POSSIBLE CAUSE Vacuum leakage IAC valve...

Page 142: ... PNP PID Are PIDs okay See F1 25 PCM INSPECTION except for GF4A EL models See Section F for GF4A EL models No TP V PID Inspect TP sensor MAF V MAF PID Inspect MAF sensor VS VSS PID Inspect VSS BRK SW BOO PID Inspect brake switch TR SW TR PID Inspect TR switch NL SW CPP PNP PID Inspect neutral switch 7 Verify test results If okay return to diagnostic index to service any additional symptoms N010 EN...

Page 143: ...or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE See Section F Caution Disconnecting connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector Always clean the quick release connector joint area before disconnecting connecting and make s...

Page 144: ...ion Yes Go to next step No Adjust CKP sensor 7 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 fuel injector Spark plug is grayish white Inspect for clogged fuel injector No Install spark plugs on original cylinders Go to next step 8 Remove and shake PCV valve Does PCV valve rattle Yes G...

Page 145: ...e gauge to A C low and high pressure side lines Turn A C on and measure low side and high side pressures Are pressures within specifications See Section U Yes Go to next step No If A C is always on go to symptom troubleshooting No 23 A C is always ON or A C compressor runs continuously For other symptoms inspect following Refrigerant charging amount Condenser fan operation 15 Disconnect vacuum hos...

Page 146: ...s injury and damage Always keep sparks and flames away from fuel Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE See Section F Caution Disconnecting connecting the quick release connector without cleaning it may possibly c...

Page 147: ...t or covered with carbon Inspect for fuel leakage from fuel injector Spark plug Is grayish white Inspect for clogged fuel injector No Install spark plugs on original cylinders Go to next step 8 Remove and shake PCV valve Does PCV valve rattle Yes Go to next step No Replace PCV valve 9 Is there restriction in exhaust system Yes Inspect exhaust system No Go to next step 10 Install fuel pressure gaug...

Page 148: ...g parts 17 Is engine compression correct Yes Inspect following Valve timing Automatic transaxle ATX Clutch MTX Brake system for dragging No Inspect for cause 18 Verify test results If okay return to diagnostic index to service any additional symptoms N0 12 KNOCKING PINGING ACCELERATION CRUISE 12 Knocking pinging acceleration cruise DESCRIPTION Sound is produced when air fuel mixture is ignited by ...

Page 149: ...f cm2 30 36 psi Yes Go to next step No Zero or low Inspect fuel pump unit circuit Inspect for open fuel pump body relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line 5 Install vacuum gauge to intake manifold Start engine Does fuel pressure gauge reading increa...

Page 150: ... Irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE See Section F Caution Disconnecting connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector Always clean the quick release connector joint area before disconnecting connecting and make sure that It Is free of foreign ma...

Page 151: ...t at idle Fuel line pressure 210 260 kPa 2 1 2 6 kgf cm2 30 36 psi Yes Go to next step No Zero or low Inspect fuel pump unit circuit Inspect for open fuel pump body relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line 6 Remove and shake PCV valve Does PCV valve...

Page 152: ...t this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR PROCEDURE See Section F Caution Disconnecting connecting the quick release connector without cleaning It may possibly cause damage to the fuel pipe and quick release connector Always clean the quick release connector joint area before disconnecting connecting and make sure that it is free of foreign material Diagnostic Procedure STEP ...

Page 153: ...60 seconds when ignition switch is turned on Fuel line pressure 210 260 kPa 2 1 2 6 kgf cm2 30 36 psl Yes Go to next step No Inspect pressure regulator for high pressure cause 8 Remove and shake PCV valve Does PCV valve rattle Yes Go to next step No Replace PCV valve 9 Inspect for fuel saturation inside charcoal canister Is excessive amount of liquid fuel present in canister Yes Replace charcoal c...

Page 154: ...p No Service as necessary Repeat Step 1 2 Connect NGS tester to DLC Turn ignition switch on Retrieve any DTC Is any DTC displayed Yes No DTC is displayed Go to next step No DTC is displayed Go to appropriate DTC test 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 following and repair or replace as necessary Refrigerant charging amo...

Page 155: ...Inspect and service heater for leakage No Go to next step 8 Are there any leakage at coolant hoses and or radiator Yes Replace malfunctioning parts No Go to next step 9 Cool down the engine Remove thermostat and inspect operation See Section E Is thermostat okay Yes Engine coolant temperature and thermostat are okay inspect engine block for leakage or blockage No Access ECT V PID on NGS tester Ins...

Page 156: ...ults If okay return to diagnostic index to service any additional symptoms NO 18 EXHAUS1r SMOKE 18 Exhaust smoke DESCRIPTION Blue black or white smoke from exhaust system POSSIBLE CAUSE Blue smoke Burning oil PCV valve malfunction Engine internal oil leakage White smoke Water in combustion Cooling system coolant loss malfunction Engine internal coolant leakage Black smoke Rich fuel mixture Air cle...

Page 157: ... as necessary Repeat Step 4 5 Connect NGS tester to DLC Turn ignition switch on Retrieve any DTC Is any DTC displayed Yes DTC Is displayed Go to appropriate DTC test No No DTC is displayed Go to next step 6 Install fuel pressure gauge between fuel main pipe and fuel distributor Start engine and run it at idle Measure fuel line pressure at idle Is fuel line pressure correct at idle Fuel line pressu...

Page 158: ... of foreign material Diagnostic Procedure STEP INSPECTION RESULTS ACTION 1 Visually inspect for fuel leakage at fuel injector O ring and fuel line Service as necessary Install fuel pressure gauge between fuel main pipe and fuel distributor Start engine and run it at idle Then stop engine Does fuel line pressure remain within specification for 60 seconds when ignition switch is turned on and off Fu...

Page 159: ...seness intake air system leakage No Go to next step 5 Is rap or roar sound present Yes Inspect exhaust system for loose parts No Go to next step 6 Is knock sound present Yes Go to symptom troubleshooting No 12 Knocking pinging No If noise comes from engine internal inspect for friction gear or HLA noise 7 Verify test results If okay return to diagnostic index to service any additional symptoms NO ...

Page 160: ... switch on and set blower fan at any speed Does A C SW or ACCS PID read on Yes Inspect refrigerant pressure switch operation If switch is okay go to next step No Inspect for following A C switch is stuck open Open circuit between refrigerant pressure switch and PCM terminal 41 Open circuit of blower motor fan switch and resister if blower motor does not operate Evaporator temperature sensor and A ...

Page 161: ...ff A C switch Note A C SW PID should read off when turning A C switch off If A C SW PID reading remains on short to GND circuit may be present Does A C SW PID reading remain on Yes Inspect for following Short to GND circuit between A C switch and A C amplifier Short to GND circuit between A C amplifier and refrigerant pressure switch No Inspect for stuck closed A C switch 5 Verify test results If ...

Page 162: ...priate flow chart No Go to next step 2 Inspect following Electrical connections Vacuum lines Are all items okay Yes Go to next step No Service as necessary Repeat Step 2 3 Connect NGS tester to DLC Turn ignition switch on Retrieve any DTC Is any DTC displayed Yes DTC Is displayed Go to appropriate DTC test No No DTC Is displayed Go to next step 4 Install fuel pressure gauge between fuel main pipe ...

Page 163: ...ine Accurately spray water on suspect component wire component or vacuum line related to possible fault area Are any PID values out of range or suddenly change and go back into range or was there a noticeable engine misfire stumble Yes Fault occurred while spraying on component Replace part and verify repair Fault occurred while spraying wiring Inspect each wire for corrosion bent or loose termina...

Page 164: ... disconnected Disconnect PCM connector Measure resistance between PCM connector terminal 31 and constant voltage circuit at appropriate sensor connector Is resistance less than 5 0 Q Yes Inspect constant voltage at TP sensor connector again If constant voltage is still out of range replace PCM No Repair open constant voltage circuit 8 Note The purpose of this step is to determine if NGS tester is ...

Page 165: ...lowing 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 Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete BEFORE REPAIR PROCEDURE and AFTER REPAIR P...

Page 166: ...ve items okay Yes Inspect for open circuit between suspected fuel injector connector terminal and following PCM connector terminals For 1 cylinder 75 For 2 cylinder 101 For 3 cylinder 74 For 4 cylinder 100 No Replace fuel injector 9 Is air cleaner element free of restriction Yes Go to next step No Replace air cleaner element 10 Carry out spark test Is strong blue spark visible at each cylinder Yes...

Page 167: ...ON except for GF4A EL models See Section F for GF4A EL models Inspect PCM GND condition No Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect pulsation damper High Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line 17 Verify test results If o...

Page 168: ...proceed to the next step If there is a difference of 0 5V or more inspect the following points concerning the PCM connector Female terminal opening looseness Coupler pin holder damage Pin discoloration blackness Harness pin crimp is loose or disconnected 2 When you get an unusual signal measure the 2 sensor terminal voltage If there is a 0 5V or more difference between the sensor and NGS voltages ...

Page 169: ...1 Confirm that terminal sensor 4 is at 0V If it is at 0V inspect the sensor If necessary replace the sensor If not at 0V inspect for the following Open circuit in harness Female terminal opening looseness Coupler pin holder damage Pin discoloration blackness Harness pin crimp is loose or disconnected Thermistor type Intake air temperature IAT and engine coolant temperature ECT sensors PCM Investig...

Page 170: ...ness Female terminal opening looseness Coupler pin holder damage Pin discoloration blackness Harness pin crimp is loose or disconnected ENGINE SYSTEM INSPECTION Idle Air Control IAC Inspection Engine coolant temperature ECT compensation inspection 1 Connect the SSTs NGS tester to DLC PROGRAM CARD 2 Select the PID DATA MONITOR AND RECORD function on the NGS display 3 Select the following PIDs ECT I...

Page 171: ...lectrical loads E L are turned on Equal load with Headlight Fan switch 3rd or higher Cooling fan A C switch and fan switch are turned ON Steering wheel turned fully Pressure Regulator Control Inspection Warning Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete the BEFORE REP...

Page 172: ...d increase the engine speed to 4000 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 when the engine speed drops below 2500 rpm If not as specified carry out the following ECT sensor inspection Neutral clutch switch inspection MTX TR switch inspection ATX Fuel Pump Operation Inspection Except for GF4A EL models ...

Page 173: ...ter to the DLC and verify that the DTC P1496 P1497 P1498 P1499 or P1409 are shown Carry out troubleshooting of DTC P1496 P1497 P1498 P1499 or P1409 For GF4A EL models If no code is displayed remove EGR valve and check if the valve is stuck If the valve is stuck replace the EGR valve Except for GF4A EL models Go to next step PROGRAM CARD 3 Start the engine and run it at idle 4 Select the SIMULATION...

Page 174: ...nspection 11 Select the SIMULATION TEST function on the NGS display 12 Select PRGV PID 13 Press START 14 Increase the duty value of the purge solenoid valve to 50 and inspect if the operation sound of the valve is heard If the operation sound is heard inspect for loose or damaged vacuum hose Intake manifold purge solenoid valve charcoal canister If the operation sound is not heard carry out the pu...

Page 175: ...cooling fan is operating when engine is hot If the cooling fan does not operate inspect as follows 1 Connect the SSTs NGS tester to the DLC PROGRAM CARD 2 Select the SIMULATION TEST function on the NGS display 3 Select IG ON TEST mode 4 Select FAN 3 PID 5 Press START 6 Verify that the cooling fan is operating If the cooling fan operates inspect the ECT sensor DTCs P0117 0118 If the cooling fan doe...

Page 176: ...ion sound is not heard check the following Cooling fan relay Open circuit in wiring harness and Connectors Main relay cooling fan relay PCM 7 Turn the A C switch and fan switch ON 8 Verify that the cooling fan is operating 9 If does not operate but operation sound is heard from A C compressor electromagnetic clutch inspect as follows If the operating sound is heard check for open circuit between c...

Page 177: ...R AND RECORD F2 14 SERVICE SUPPLEMENTAL SERVICE INFORMATION F2 15 INTAKE AIR SYSTEM F2 15 ACCELERATOR PEDAL COMPONENT REMOVAL INSTALLATION F2 15 ACCELERATOR PEDAL DISASSEMBLY ASSEMBLY F2 15 ACCELERATOR POSITION SENSOR ADJUSTMENT F2 16 IDLE SWITCH ADJUSTMENT F2 16 FULLY OPEN STOPPER ADJUSTMENT F2 16 CONTROL SYSTEM F2 18 PCM INSPECTION F2 18 IDLE SWITCH INSPECTION F2 21 ACCELERATOR POSITION SENSOR I...

Page 178: ...roved Improved Reliability A potentiometer type two accelerator position signals circuit accelerator position sensor has been adoptedtol improve the reliability of the accelerator position sensor Due to the change of the accelerator position sensor type a detection condition item has been added to DTC P0120 for accelerator position sensor signal circuit SPECIFICATIONS Item RF Turbo Air cleaner ele...

Page 179: ...OUTLINE SYSTEM WIRING DIAGRAM S m ç g fT I C g 3 3 21 A m Hi p È a t ï S 3 M h d 0H ÜB 1 Hl J e F2 3 ...

Page 180: ...nsor No 1 ECT sensor Accelerator position sensor EGR position sensor Boost sensor PCM control relay Condenser fan relay_______ 26 Condenser fan motor 27 A C relay 28 Magnetic clutch 29 Refrigerant pressure switch 30 A C pressure switch 31 A C amplifier 32 Cooling fan relay 33 Cooling fan motor 34 Vacuum switch 35 Fuel warmer 36 Instrument cluster 37 Grow indicator light 38 VSS 39 Generator warning...

Page 181: ...on sensor main Accelerator pedal position X X Idleswitch Accelerator pedal open or closed X IATsensor Intake air temperature X Two IAT sensors are equipped to measure IAT before and after supercharging Neutral Clutch switch Load No load condition X Pumpspeed sensor Engine speed X Function is different Sensor name has been changed from NE sensor to pump speed sensor TDCsensor Crank angle standard p...

Page 182: ...alve relay IDM power X Power to IDM IDM Spill valve drive X Power for driving spill vavle EGR solenoid valve vacuum EGR valve drive X EGR solenoid valve vent EGR valve drive X Opens closes vacuum passage which acts on EGR valve diaphragm Glow indicator light Glow indicator light control X Glow plug relay Glow plug drive X A C relay A C control X Condenser fan relay Condenser fan control X Cooling ...

Page 183: ...CONTROL SYSTEM COMPONENT LOCATION F2 7 ...

Page 184: ... temperature sensor Boost sensor Clutch switch___________ EGR valve position sensor Injection pump EPROM Battery DLC TCV 16 EGR solenoid valve Vent 17 EGR solenoid valve Vacuum 18 Spill valve relay 19 PCM control relay 20 FSO solenoid relay 21 Glow plug relay 22 A C relay 23 Condenser fan relay 24 Cooling fan relay 25 IDM 26 PCM 27 R H D 28 L H D 29 Clutch pedal 30 Accelerator pedal F2 8 ...

Page 185: ...ition main circuit and monitor circuit As in previous models the main circuit is used for the controls operated by the PCM e g fuel injection amount control The monitor circuit is used for detecting malfunctions in the accelerator position sensor When voltage difference between the main and monitor circuits increases the PCM determines that the accelerator position sensor is malfunctioning and sto...

Page 186: ...e from IAT No 1 sensor is below 0 142 V or above 4 915 V Fixes intake air temperature No 1 at 40 C 104 F 1 49 V P0115 JIM ECT signal circuit Input voltage from ECT sensor is below 0 142 V or above 4 915 V Fixes engine coolant temperature at 60 C 140 F P0120 Accelerator position signal circuit Input voltage from accelerator position sensor is below 0 3 V or above 4 7 V when engine switch is turned ...

Page 187: ...r more than 5 0 sec while driving in following condition Engine speed is over 2800 rpm Neutral switch is off Sets vehicle speed 0 km h 0 mph Operates A C cut control P0510 ilil Idle switch signal circuit PCM detects for more than 1 0 second that output voltage from accelerator position sensor is below 1 0 V with idle switch off P0606 1 PCM internal circuit PCM does not read DTC from output devices...

Page 188: ... Code word is unregistered Immobilizer Code word numbers are not registered in PCM P1621 with immo bilizer system i Code words do not match Immobilizer Code word stored in PCM and immobilizer unit do not match P1622 with Immo bilizer system ID numbers do not match Immobilizer ID numbers stored in immobilizer unit and PCM do not match This DTC is indicated only after immobilizer unit is replaced an...

Page 189: ...s started or engine switch on X P0606 PCM Engine is started or engine switch on X P1110 IAT sensor No 2 Engine is started or engine switch on X P1182 FSO solenoid Engine is started or engine switch on X P1189 Pump speed sensor Engine is started X P1196 Engine switch Engine is started X P1298 IDM Engine is started X P1402 EGR valve position sensor Engine is started or engine switch on X P1602 1 Imm...

Page 190: ... solenoid valve vacuum 1K EGRVENT EGR solenoid valve vent 10 FAN2 Condenser fan control ON OFF 1N FAN3 Cooling fan control ON OFF 3Q FLT Fuel temperature sensor C F 2I FLTV Fuel temperature signal voltage V 2I IAT IAT sensor No 1 C F 2E IAT V IAT No 1 signal voltage V 2E IATDC IAT sensor No 2 C F 2K IATDC V IAT No 2 signal voltage V 2K IG SW Engine switch ON OFF 1F MAP Boost sensor kPa Hg 2C MAP V...

Page 191: ... Inspection procedure has been added INTAKE AIR SYSTEM ACCELERATOR PEDAL COMPONENT REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove in the order indicated in the table 3 Install in the reverse order of removal 4 Perform IDLE SPEED INSPECTION See Section F2 1 Accelerator position sensor connector 2 Accelerator pedal component ACCELERATOR PEDAL DISASSEMBLY ASSEMBLY 1 Disassemble...

Page 192: ...in the idle switch Tightening torque 15 16 Nm 1 5 1 7 kgf m 11 12 ft lbfj 4 Press the accelerator pedal gradually by hand and verify that the output voltage of the PCM 2F terminal accelerator position sensor is within the specification when the output voltage of the PCM 1T terminal idle switch changes to B from below 1 0 V Specification 1 0 1 2 V 5 If not as specified loosen the locknut adjust the...

Page 193: ...pecification If not as specified loosen the locknut and adjust the position of the fully open stopper so that the voltage of the PCM 2F terminal is within specification under the condition of Step 1 Specification 3 60 3 88 V 3 Tighten the locknut Tightening torque 4 21 6 17 N m 43 0 62 9 kgf cm 37 4 54 5 in lbf F2 17 ...

Page 194: ...pect following PIDs RPM TP V ECTV A CSW Inspect A C relay See Section U 10 A C SW A C switch ON OFF A C switch and fan switch is on at engine switch on ON A C switch is off at engine switch on OFF Inspect refrigerant pressure switch See Section U 1S B Battery positive voltage V Engine switch is on B4 Inspect main relay See Section F2 Inspect battery See Section G 1B BARO Barometric pressure In PCM...

Page 195: ...F2 2E IAT V IATsignal No 1 voltage V Intake air temperature is 20 C 68 F 2 2 2 5 V Intake air temperature is 30 C 86 F 1 7 1 9 V Inspect IAT sensor See Section F2 2E IATDC IAT sensor No 2 C F Intake air temperature is 20 C 68 F 20 C 68 F Inspect IAT sensor See Section F2 2K IATDC V IAT signal voltage No 2 V Intake air temperature is 20 C 68 F 2 2 2 5 V Intake air temperature is 30 C 86 F 1 7 1 9 V...

Page 196: ...n sensor connector vehicle side terminal A and body GND using an ohmmeter If there is continuity repair the related harnesses 2 in When measurement voltage is B i Turn the engine switch off ii Disconnect the battery positive harness and battery negative harness iii Verify there is no continuity between the accelerator position sensor connector vehicle side terminal A and battery positive harness u...

Page 197: ...ted 1 Verify that the accelerator pedal and idle switch are properly installed See F2 15 ACCELERATOR PEDAL DISASSEMBLY ASSEMBLY 2 Turn the engine switch on 3 Monitor the voltage of PCM terminal IT Accelerate the accelerator pedal gradually and hold it at B Verify that the voltage of PCM terminal 2F is within the specification If not as specified carry out the accelerator position sensor inspection...

Page 198: ...sition Sensor Inspection SHORT CORD A X G B D F H SHORT CORD SIDE CONNECTOR VIEW FROM TERMINAL SIDE ACCELERATOR POSITION SENSOR n X n A I B C D SHORT CORD SIDE CONNECTOR VIEW FROM TERMINAL SIDE Circuit Open Short Inspection 1 Inspect for an open or short circuit in the following wiring harnesses If there is an open or short circuit repair or replace wiring harnesses Open circuit Constant voltage c...

Page 199: ...No Go to next step 2 Implement PID DATA MONITOR AND RECORD TP V and TP2 V of DIAGNOSTIC DATA LINK using NGS Is the voltage as specified Yes Go to next step No Go to Step 4 3 Verify that the accelerator pedal and idle switch are properly installed See F2 15 ACCELERATOR PEDAL DISASSEMBLY ASSEMBLY Yes Go to Step 8 No Go to Step 10 4 Disconnect accelerator position sensor connector Turn engine switch ...

Page 200: ...ch on Is there 5V at idle switch terminal A Yes Go to next step No Check for open or short circuit in wiring harness PCM terminal 1T Idle switch terminal 3 Is there continuity between idle switch connector terminal B and body earth Yes Go to next step No Replace idle switch 4 Inspect installation condition of idle switch and accelerator position sensor Are they okay Yes Go to next step No Adjust i...

Page 201: ...ENGINE ELECTRICAL SYSTEM FEATURES OUTLINE G 2 OUTLINE OF CONSTRUCTION G 2 FEATURES G 2 SPECIFICATIONS G 2 SERVICE SUPPLEMENTAL SERVICE INFORMATION G 3 CHARGING SYSTEM G 3 GENERATOR INSPECTION G 3 G 1 ...

Page 202: ...n eliminated RF Turbo SPECIFICATIONS Item Specification FP FS FS Hi power RF Turbo Battery Voltage V 12 Type and capacity 5 hour rate Ah 55D23L 48 75D26L 52 1 95D31 L 64 115D31 L 70 1 Generator Output V A 12 80 Regulated voltage V Controlled by PCM 14 1 14 7 20 C 68 F Self diagnosis function Not equipped Integrated in PCM Equipped Ignition system Type Dl Spark advance Electronic Firing order 1 3 4...

Page 203: ...he battery is fully charged Charge it if necessary 2 Verify that the drive belt deflection tension is within the specification See Section B1 Replace it if necessary 3 Turn the ignition switch to ON and verify that the generator warning light illuminates If not as specified inspect the generator warning light wiring harnesses between the battery generator warning light and PCM terminal 42 When the...

Page 204: ...MANUAL TRANSAXLE FEATURES OUTLINE J 2 OUTLINE OF CONSTRUCTION J 2 SPECIFICATIONS J 2 D J 1 ...

Page 205: ...r ratio have been changed FP FS and FS Hi power models SPECIFICATIONS Item Specification Engine type FP FS FS Hi power RF Turbo Transaxle type G25M R Transaxle control Floor shift Operation system Rod Shift assist Forward Synchromesh Reverse Selective sliding and synchromesh Gear ratio 1st 3 666 3 454 2nd 1 842 1 833 3rd 1 310 4th 0 970 5th 0 755 0 717 Reverse 3 166 3 454 Final gear ratio Except w...

Page 206: ...AUTOMATIC TRANSAXLE GF4A EL FEATURES OUTLINE K1 2 OUTLINE OF CONSTRUCTION K 1 2 SPECIFICATION K1 2 K1 1 ...

Page 207: ...atio 3 823 Speedometer gear ratio number of driven drive gear teeth 14 15 inch wheel 0 80 20 25 16 inch wheel 0 84 21 25 Automatic transaxle fluid ATF Type ATF M III or equivalent e g Dexron II Capacity L Us qt Imp qt 8 0 8 5 7 0 Torque converter stall torque ratio 2 36 Hydraulic system Number of drive driven plates Forward clutch 3 3 Coasting clutch 2 3 3 4clutch 4 4 Reverse clutch 2 2 Low and re...

Page 208: ...TRANSAXLE FLUID TEMPERATURE TFT SENSOR REMOVAL INSTALLATION K2 35 INPUT TURBINE SPEED SENSOR INSPECTION K2 35 K2 INPUT TURBINE SPEED SENSOR REMOVAL INSTALLATION K2 35 VEHICLE SPEED SENSOR VSS INSPECTION K2 36 VEHICLE SPEED SENSOR VSS REMOVAL INSTALLATION K2 38 SOLENOID VALVES INSPECTION K2 38 SOLENOID VALVES REMOVAL INSTALLATION K2 40 HOLD INDICATOR LIGHT INSPECTION K2 40 PCM INSPECTION K2 40 PCM ...

Page 209: ... LO W K2 146 NO 12 TORQUE CONVERTER CLUTCH TCC NON OPERATION K2 146 NO 13 NO KICKDOWN K2 147 NO 14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING K2 147 NO 15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE K2 148 NO 16 JUDDER UPON TORQUE CONVERTER CLUTCH TCC OPERATION K2 148 NO 17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION RANGE K2 149 NO 18 EXCESSIVE SHIFT SHOCK IS FELT ...

Page 210: ...25 Reverse 2 648 Final gear ratio 3 904 ATF Type ATF M III or equivalent e g Dexron II Capacity L US qt Imp qt 7 2 7 6 6 3 Torque converter stall torque ratio 2 250 2 000 Hydraulic system Forward clutch number of drive driven plates 4 4 3 4 clutch number of drive driven plates 3 3 Reverse clutch number of drive driven plates 2 2 Low and reverse brake number of drive driven plates 5 5 Band servo Se...

Page 211: ...transaxle of the face lifted 626 GF is carried over from that of the current 323 BJ CROSS SECTIONAL VIEW 8 2 4 brake band 9 Low and reverse brake 10 One way clutch 11 Primary gear 12 Secondary gear 13 Output gear 14 Differential 1 Torque converter 2 Oil pump 3 Forward clutch 4 Front planetary gear 5 Rear planetary gear 6 3 4 clutch 7 Reverse clutch K2 4 ...

Page 212: ...enoids shift solenoids D and E And the clutch engagement pressure is controlled by the duty cycle type solenoids shift solenoids A B and C Powertrain mechanism The driving force from the engine is transmitted through the torque converter to the transaxle The transmitted driving force operates each clutch and brake according to the clutch engagement pressure from the duty cycle type solenoid and th...

Page 213: ...OFF HOLD 3GR 1 000 X X X X X OPEN OPEN OPEN OFF OFF S 4GR 3 0 725 X X X CLOSED OPEN OPEN ON OFF 2GR 1 497 X X X OPEN OPEN CLOSED OFF OFF HOLD 3GR 3 1 000 i f X X X X X OPEN OPEN OPEN OFF OFF 4GR 3 0 725 X X X CLOSED OPEN OPEN ON O FF 1GR 2 816 A X OPEN CLOSED CLOSED OFF OFF Non 2GR 1 487 f X X X OPEN OPEN CLOSED OFF OFF HOLD 3GR 3 1 000 1 X X X X X OPEN OPEN OPEN OFF OFF i 4GR 3 0 725 T X X X CLOS...

Page 214: ...the planetary gear changes the gear ratio according to the vehicle driving condition Structure The powertrain mechanism of the FN4A EL type consists of three pairs of clutches brake band brake one way clutch and two pairs of single type planetary gears 1 Forward clutch 2 One way clutch 3 Low and reverse brake 4 Front planetary gear 5 Rear planetary gear 6 2 4 brake band 7 Reverse clutch 8 3 4 clut...

Page 215: ...e is backing 2 4 brake band Locks rotation of reverse drum and fixes rear sun gear Operates in second or fourth gear position Low and reverse brake Fixes rotation of front internal gear Operates when vehicle is backing or in first gear position L range HOLD One way clutch Locks counterclockwise rotation of front internal gear in first gear position Planetary gear The planetary gear functions as a ...

Page 216: ...rol by the linear type pressure control solenoid and the clutch engaging pressure control by duty cycle type shift solenoids A B and C excellent shift quality is obtained This system is the same as that of the current 323 BJ 1 R H D 2 L H D 3 HOLD indicator light 4 Speedometer 5 Brake swich 6 PCM 7 HOLD switch 8 Selector indicator light 9 TP sensor 10 DLC 11 MAF sensor 12 ECT sensor 13 VSS 14 Inpu...

Page 217: ...B 21 Shift solenoid C 22 Shift solenoid D 23 Shift solenoid E 24 Pressure control solenoid 25 Speedometer signal 26 HOLD indicator light 1 PCM 2 Engine control system 3 Transaxle control system 4 On board diagnostic system 5 Input signals 6 TP sensor 7 CKP sensor 8 MAF sensor 9 Brake switch 10 ECT sensor 11 Engine control output signals 12 DLC 13 HOLD switch K2 10 ...

Page 218: ...e mode control Changes the shift point to prevent frequent shifting up down when climbing or descending hills On board diagnostic system Detects and or memorizes failure of input output part and transaxle condition COMPONENT DESCRIPTIONS ELECTRONIC CONTROL Part name Function HOLD switch Selects driving modes HOLD and changes driving patterns TR switch Detects selector lever ranges positions TP sen...

Page 219: ...r descending hill On board diagnostic function Input HOLD switch X TR switch X X X X TP sensor X X X X X Input turbine speed sensor X X X X X v s s X X X X X X Brake switch X TFT sensor X X X X X X ECT sensor X X CKP sensor X X X X X MAF sensor X X X X X X Output Pressure control solenoid X X Shift solenoid A X X X X X X Shift solenoid B X X X X Shift solenoid C X X X X Shift solenoid D X X x Shif...

Page 220: ...edures displayed on the NGS tester The NGS tester is connected to the DLC and is used for the on board diagnostic system Also it is possible to read DTCs only with a self diagnosis checker or a voltmeter BLOCK DIAGRAM 10 Engine transaxle control system 11 Input system 12 TEN 13 FEN 14 KLN 15 NGS 16 Self diagnosis checker 17 Voltmeter 18 Output system 1 PCM 2 On boad diagnostic system 3 Failure ind...

Page 221: ...re control solenoid P0745 Pressure control solenoid valve malfunction P0745 Pressure control solenoid valve malfunction Shift solenoid A P0751 Shift solenoid A malfunction stuck off P0753 Shift solenoid A malfunction electrical P0752 Shift solenoid A malfunction stuck on P0753 Shift solenoid A malfunction electrical Shift solenoid B P0756 Shift solenoid B malfunction stuck off P0758 Shift solenoid...

Page 222: ...of TFT sensor output voltage to PCM is below 0 06 V in normal condition during failure detection period Input Turbine Speed Sensor Circuit Malfunction P0715 No input turbine speed sensor signal is inputs to PCM when vehicle speed is 40 km h 25 mph or above and shift lever position is at D S or L during failure detection period Shift or Pressure Control Solenoid Valve Circuit Malfunction If there i...

Page 223: ... PCM it U M r i A INPUT TURBINE SPEED SENSOR B CKP SENSOR ATX Shift Solenoid Valves Stuck On or Off Determines malfunctioning solenoid valve based on combination of detected DTCs incorrect gear P0731 P0732 P0733 or P0734 and TCC malfunction P0741 P0742 Shift solenoid A stuck off P0751 When detected gear 4 incorrect P0734 Shift solenoid A stuck on P0752 Forward clutch drum revolution does not drop ...

Page 224: ...4TH 0 6 or à 1 249 ENGINE FAILURE PCM r ÍA ATX A INPUT TURBINE SPEED SENSOR B VSS Gear 1 incorrect P0731 Revolution ratio of forward clutch drum revolution to differencial gear case revolution is below 2 157 while in 1GR Gear 2 incorrect P0732 Revolution ratio of forward clutch drum revolution to differencial gear case revolution is below 1 249 or 2 157 or above while in 2GR Gear 3 incorrect P0733...

Page 225: ...ts TCC and maximizes line pressure Inhibition P0742 TCC stuck on Inhibits TCC and maximizes line pressure Inhibition P0745 Pressure control solenoid valve malfunction Available P0751 Shift solenoid A malfunction stuck off Inhibits 4GR and TCC and maximizes line pressure Inhibition P0752 Shift solenoid A malfunction stuck on Inhibits 1GR 2GR and 3GR and maximizes line pressure Available P0753 Shift...

Page 226: ...e signal voltage V 37 DSW TR switch D range switch ON OFF 6 HOLD LP HOLD indicator control signal in PCM ON OFF 43 HOLD SW HOLD switch ON OFF 29 LSW TR switch L range switch ON OFF 7 LINE Pressure control solenoid control signal in PCM A 44 81 RSW TR switch R position switch ON OFF 32 SSW TR switch S range switch ON OFF 9 SHIFT A Shift solenoid A control signal in PCM 82 SHIFT B Shift solenoid B c...

Page 227: ...y value 0 100 X 102 SHIFT D 2 Shift solenoid D ON or OFF X 27 SHIFT E 2 Shift solenoid E ON or OFF X 1 2 A simulation test can be performed but inspection is not possible as the line pressure does not change and solenoid valve is barely audible DIAGNOSTIC SUPPORT PROCEDURE Diagnosis for the TR switch and or TR switch circuits is possible by performing the following procedure 1 Connect the NGS to t...

Page 228: ...nges and R positions in the same manner as in Steps 4 5 7 Stop the engine then replace the SST 49 B019 901A with the gauge of the SST 49 0378 400B 8 Start the engine 9 Firmly depress the brake pedal with the left foot 10 Shift the selector lever to D range position Caution If the accelerator pedal is pressed for longer than 5 seconds while the brake pedal is pressed the transaxle could be damaged ...

Page 229: ...le could be damaged Therefore perform Steps 5 and 6 within 5 seconds of each other 5 Gently depress the accelerator pedal with the right foot 6 When the engine speed no longer increases quickly read the speed and release the accelerator pedal 7 Shift the selector lever to N 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 p...

Page 230: ...ndition Possible cause N D shift More than specification Insufficient line pressure Forward clutch slipping Oil leaking from forward clutch fluid circuit Shift solenoid A not operating properly Less than specification Forward accumulator not operating properly Shift solenoid A not operating properly Excessive line pressure N D HOLD shift More than specification Insufficient line pressure Forward c...

Page 231: ...ad test Road Test Preparation 1 Inspect the engine coolant levels See Section E 2 Inspect the engine oil levels See Section D 3 Inspect the ATF levels See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION ATF Level Inspection 4 Inspect the IG timing See F1 21 IGNITION TIMING INSPECTION 5 Inspect the idle speed See F1 23 IDLE SPEED INSPECTION Shift Diagram D range normal mode TCC o p e r a t io n a v ...

Page 232: ...not as specified inspect the PCM and ATX See K2 136 SYMPTOM TROUBLESHOOTING ITEM TABLE 6 Drive the vehicle and verify that TCC operation is obtained The operation points must be as shown in the table below If not as specified inspect the PCM and ATX See K2 136 SYMPTOM TROUBLESHOOTING ITEM TABLE 7 Select HOLD mode 8 Accelerate the vehicle at half throttle and WOT and verify that 4 3 3 2 and 2 3 shi...

Page 233: ...8 14 5 8 450 700 8 14 5 8 300 450 D4 D3 151 161 94 99 3850 4050 Kickdown WOT D3 D2 94 102 59 63 3350 3550 D2 D 1 36 42 23 26 1900 2200 D Di D2 56 62 35 38 5550 6100 WOT d2 d3 105 113 66 70 5550 5900 D3 D4 158 168 98 104 5550 5850 Di D2 43 51 27 31 4250 5100 Half throttle Q t CM Q 84 100 53 62 4400 5250 D3 D4 134 157 84 97 4700 5500 POWER d4_ d 3 37 43 23 26 950 1050 CTP D3 D2 8 14 5 8 300 450 D2 O...

Page 234: ...2 S3 105 113 66 70 5550 5900 Half throttle Si S2 43 51 27 31 4250 5100 S2 S3 84 100 53 62 4400 5250 NORMAL S4 S3 158 164 98 101 4050 4150 S CTP S3 S2 8 14 5 8 300 450 S2 S1 8 14 5 8 450 700 S4 S 3 156 166 97 102 4000 4200 Kickdown WOT S3 S2 94 102 59 63 3350 3550 S2 S1 39 45 25 27 2100 2350 HOLD All round S4_ S3 158 164 98 101 4050 4150 S3 S2 104 110 65 68 3700 3850 LRange Test 1 Perform road test...

Page 235: ... the ATF is muddy or varnished If the ATF smells strange or unusual ATF condition Condition Possible cause Clear red Normal Light red pink Contaminated with water Broken oil cooler inside of radiator Poor breather hose installation Problem could be occurring to parts inside the transaxle by water contamination It is necessary to overhaul transaxle and detect defected parts If necessary exchange tr...

Page 236: ...22 30 inlbf 5 Add the specified ATF until ATF level reaches lower notch of dipstick type of ATF through the oil filler tube 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 the brake pedal 6 Shift the selector lever to P position 7 Verify that the ATF level is in the HOT range 65 C 149 F while the engin...

Page 237: ...position with the ignition switch at the ON position If not as specified adjust the TR switch 3 Verify that the indication on the indicator light meets the lever position in each range when shifting the selector lever from P position to L range For vehicles with AT indicator light If not as specified adjust the TR switch Continuity Inspection Caution Water or foreign objects entering the connector...

Page 238: ...component and fresh air duct See Section F1 8 Connect the negative battery cable TRANSAXLE RANGE TR SWITCH REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the fresh air duct and air cleaner component See Section F1 3 Remove the splash shield 4 Disconnect the TR switch connector TR SWITCH CONNECTOR 5 Remove the clip and disconnect the selector cable 6 Remove the manual shaft n...

Page 239: ...t where there is continuity between the terminals 15 Tighten the TR switch mounting bolts Tightening torque 7 9 10 7 Nm 80 110 kgf cm 69 5 95 4 inlbf 16 Tighten the manual shaft nut Tightening torque 32 46 N m 3 2 4 7 kgfm 24 33 ft lbf 21 Inspect for continuity at the TR switch See TRANSAXLE RANGE TR SWITCH INSPECTION Continuity Inspection If not as specified readjust the TR switch See K2 33 TRANS...

Page 240: ... switch to the point where there is continuity between the terminals 10 Tighten the TR switch mounting bolts Tightening torque 7 9 10 7 N m 80 110 kgfcm 69 5 95 4 in lbf 11 Select the selector lever to N position and TR switch are aligned 12 Connect the TR switch connector 13 Install the clip to the selector cable as shown in the figure SELECTOR CABLE 14 Connect the selector cable to the manual sh...

Page 241: ...CONNECTOR H E 6 Install the air cleaner component and fresh air duct See Section F1 7 Connect the negative battery cable Off Vehicle Inspection Warning 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 K2 46 CONTROL VALVE BODY REMOVAL On Vehicle Removal 2 Remove the transaxle connector 3 ...

Page 242: ... sensor INPUT TURBINE SPEED SENSOR COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL SIDE 5 Connect the input turbine speed sensor connector 6 Install the air cleaner component See Section F1 INPUT TURBINE SPEED SENSOR REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the air cleaner component See Section F1 3 Disconnect the input turbine speed sensor connector 4 Install a new TFT se...

Page 243: ... 7 Select the PCM on the NGS display and press TRIGGER 8 Select the VS on the NGS display and press START 9 The FREQUENCY METER screen will be displayed Note The selected threshold voltage indicated on the FREQUENCY METER SCREEN should be 2 VOLTS DC If an incorrect threshold voltage is selected the calculated frequency value will be incorrect Threshold voltage should be in the DC range Press AC DC...

Page 244: ...S connector terminal A to main relay terminal D If a short circuit is found repair the malfunctioning wiring harness If there is no short circuit perform the sensor rotor inspection VSS HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Sensor rotor inspection 1 Remove the VSS See K2 38 VEHICLE SPEED SENSOR VSS REMOVAL INSTALLATION 2 Shift the selector lever to N position 3 Check sensor rotor surface ...

Page 245: ...r can cause a poor connection or corrosion Be sure not to drop water or foreign objects on the connector when disconnecting it If foreign materials are stuck to the VSS disturbance by magnetic flux can cause sensor output to be abnormal and there by negatively affect control Make sure that foreign materials such as Iron filings are not stuck to the VSS during Installation 1 Disconnect the negative...

Page 246: ...es is small perform inspection in a quiet place If the click is not heard inspect the transaxle harness If transaxle harness is okay perform the resistance inspection off vehicle inspection If there is a problem repair or replace the transaxle harness Resistance Inspection Off Vehicle Inspection 1 Remove the control valve body See K2 40 SOLENOID VALVES REMOVAL INSTALLATION 2 Measure the resistance...

Page 247: ...ENOID C SHIFT SOLENOID B BOLT BOLT SHIFT SOLENOID E 6 Install the control valve body See K2 46 CONTROL VALVE BODY INSTALLATION On Vehicle Installation 7 Add in ATF and with the engine idling inspect the ATF level and inspect for leakage See K2 38 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION ATF Level Inspection 8 Carry out the mechanical system test See K2 21 MECHANICAL SYSTEM TEST 9 Carry out the roa...

Page 248: ...a transaxle is dangerous It can slip off the jack and may cause serious injury 7 Remove in the order shown in the figure 8 Install in the reverse order of removal 9 Add ATF to the specified level See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 10 Carry out the mechanical system test See K2 21 MECHANICAL SYSTEM TEST Service Item Test Item Line pressure test Stall test Time lag test ATX replacem...

Page 249: ... 7 10 8 14 7 1 1 1 5 8 0 10 8 38 51 3 8 5 3 28 38 38 51 3 8 5 3 28 38 38 51 3 8 5 3 28 38 64 89 6 5 9 1 48 65 94 131 9 5 13 4 68 8 96 9 67 93 6 8 8 5 50 68 67 93 6 8 9 5 50 68 75 104 7 6 10 7 55 77 3 Nm kgf m ftlbf K2 42 ...

Page 250: ...ve shaft L H See Section M 20 Drive shaft R H See Section M 21 Joint shaft R H See Section M 22 Selector cable 23 Intake manifold stay 24 Starter See Section G 25 Torque converter installation nuts See K2 43 Torque Converter Installation Nuts Removal Note 26 No 1 engine mount bolts See K2 45 No 1 Engine Mount Bolts Installation Note 27 No 2 engine mount 28 No 4 engine mount See K2 44 No 4 Engine M...

Page 251: ...e lack 1 Set the transaxle on a jack and lift it 2 Install the transaxle mounting bolts Tightening torque A 90 116 Nm 9 1 11 9 kgf m 66 86 ftlbf B 38 51 N m 3 8 5 3 kgf m 28 38 ft lbf C 19 25 N m 1 9 2 6 kgf m 14 18 ft lbf A No 4 Engine Mount Installation Note 1 Install the No 4 engine mount bracket by passingit through the stud bolt on the transaxle 2 Match the positions of the No 4 engine mount ...

Page 252: ...uts A as shown Tightening torque 67 93 N m 6 8 9 5 kgf m 50 68 ft lbf 5 Tighten the nuts B as shown Tightening torque 75 104 N m 7 6 10 7 kgf m 55 77 3 ft lbf K2 6 Remove the SST OIL SEAL TRANSAXLE REPLACEMENT 1 Drain the ATF See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT Caution The oil seal is easily damaged by the sharp edges of the drive shaft splines Do not let the splines contact the oi...

Page 253: ...axle connectors and transaxle fluid temperature TFT sensor connector 6 Remove the oil strainer OIL STRAINER 8 Remove the accumulators and accumulator springs ACCUMULATOR CONTROL VALVE BODY INSTALLATION On Vehicle Installation Caution Be sure to align the parking rod and the manual valve PARKING ASSIST LEVER COMPONENT CONTROL VALVE BODY 1 Vr 4 rU W MANUALVALVE 1 install the accumulator springs and ...

Page 254: ...oid E Black 5 Install the ground Tightening torque 7 9 10 7 N m 80 110 kgf cm 70 95 4 in lbf TFT SENSOR SHIFT SOLENOID E SHIFT SOLENOID D SHIFT SOLENOID B PRESSURE CONTROL SOLENOID GROUND SHIFT SOLENOID C SHIFT SOLENOID A 6 Apply a light coat of silicon sealant to the contact surfaces of the oil pan and transaxle case SEALANT 7 Install the oil pan Tightening torque 5 9 7 8 N m 60 80 kgf cm 53 69 i...

Page 255: ...s covered with too much debris or particles and cannot be seen replace the oil cooler See K2 49 OIL COOLER REMOVAL INSTALLATION See K2 51 OIL COOLER DISASSEMBLY ASSEMBLY 3 If the element can be seen flush the oil cooler lines using the power flushing tool Performing back and reverse power flushing two times each does not work because debris or particles flow out from the feed pipe side of ATX Powe...

Page 256: ...n the order shown in the figure 2 Install in the reverse order of removal 3 Add ATF to the specified level See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 4 Carry out the mechanical system test See K2 21 MECHANICAL SYSTEM TEST 5 Carry out the road test See K2 24 ROAD TEST 1 Oil hose See K2 50 Oil Pipe Hose Clamp Oil Hose Installation Note 2 Hose clamp See K2 50 Oil Pipe Hose Clamp Oil Hose Ins...

Page 257: ...ipe Hose Clamp Oil Hose Installation Note 1 Apply compressed air to cooler side opening and blow any remaining grime and foreign material from the cooler pipes Compressed air should be applied for no less than one minute 3 Install the new hose clamp onto the hose 4 Verify that the hose clamp does not interfere with any other components 2 Align the marks and slide the oil hose onto the oil pipe unt...

Page 258: ...Outer Tank In Tank Oil Cooler Installation Note 3 O ring 4 Nut set 5 ATF cooler 6 Radiator Radiator Outer Tank In Tank Oil Cooler Removal Note 1 Inspect the height of the header tabs Note Do not open more tabs than necessary for tank removal 2 Insert the end of a medium tip screwdriver between the end of the header tab and the outer tank 3 Pivot the screwdriver to pry the tab away from the tank an...

Page 259: ... type pliers while rotating the pliers toward the tank O RING r C D C D 5 Verify the height of the header tabs is same as the height before removal 2 Position the radiator tank in the original direction to the core using care not to scratch the tank sealing surface with the header tabs Note Step 3 will set jaw opening to the correct specification 3 With the jaws of locking type pliers vise grips c...

Page 260: ...ATOR TESTER 7 Inspect for air leakage 1 Drive plate mounting bolts See K2 53 Drive Plate Mounting Bolts Removal Note 2 Adapter 3 Drive plate See K2 53 Drive Plate Installation Note Drive Plate Mounting Bolts Removal Note 1 Set the SST or equivalent against the drive plate 2 Remove the drive plate mounting bolts Drive Plate Installation Note Caution If the bolts are reused remove the oil sealant fr...

Page 261: ...et the SST or equivalent against the drive plate Caution When installing sealant covered bolts tighten them immediately Leaving these bolts in a half installed condition could cause them to be stuck that way due to the natural hardening or the sealant 6 Tighten the drive plate installation bolts in two or three steps as shown Tightening torque 97 102 N m 9 8 10 5 kgf m 71 75 ft lbf 7 Install the t...

Page 262: ...lever p n F t N D I S I K BUTTON NEED NOT BE r DEPRESSED BUTTON MUST BE DEPRESSED 5 Verify that the positions of the selector lever and the indicator are aligned 6 Verify that the position of the selector lever is aligned If not as specified adjust the TR switch See K2 33 TRANSAXLE RANGE TR SWITCH ADJUSTMENT 7 Verify that the vehicle operates in each selected range SELECTOR CABLE ADJUSTMENT 1 Remo...

Page 263: ... Nut 3 Selector lever 4 Seal rubber Selector Cable Installation Note 1 Shift the manual shaft to P position 2 Install the selector cable to the selector lever SELECTOR CABLE Caution Bending the selector cable in the manner shown in the figure will damage the cable and It may become loose when shifted When installing the selector cable hold It straight Note Install the selector lever to the manual ...

Page 264: ...f the end of the selector cable 5 Install the selector cable to the selector cable bracket SELECTOR CABLE 6 Verify that the selector lever to P position 7 Unlock the lock piece of the selector cable selector lever side in the order shown in the figure 8 Shift the selector lever from P position to L range and make sure that other components that area to there is no interfere the lever K2 57 ...

Page 265: ...er Connector Disassembly Note 1 Insert a thin metal from the terminal side of the connector and press down the terminal locking tab THIN METAL 2 Pull the terminal out of the connector 3 Clearance can be reduced by turning the cam clockwise 4 Install the selector lever knob and verify that the clearance is as specified If not as specified repeat from Step 2 5 Remove the selector lever knob Cam Asse...

Page 266: ...SHIFT MECHANISM 6 Apply grease to the cam as shown K2 59 ...

Page 267: ...iagnose the malfunction according to following flowchart If the DTC exists diagnose the applicable DTC See K2 62 DTC TABLE If the DTC does not exist and the HOLD indicator light flashes diagnose the applicable symptom troubleshooting See K2 136 SYMPTOM TROUBLESHOOTING ITEM TABLE HOLD indicator light AUTOMATIC TRANSAXLE ON BOARD DIAGNOSTIC FUNCTION DTC Reading Procedure See Section F1 K2 60 ...

Page 268: ...ID 20 km h 12 mph or above iv Go to Step 5 For P0710 i Start the engine ii Access VS PID using SSTs NGS tester iii Drive vehicle under following for condition 150 seconds or more while monitoring PID VS PID 20 km h 12 mph or above iv Go to Step 5 For P0711 i Decrease ATF temperature to 20 C 68 F or below ii Start the engine iii Access VS PID using SSTs NGS tester iv Drive vehicle under following c...

Page 269: ... P0134 H I H02S circuit no activity detected See F1 57 DTC P0134 P0135 H02S heater circuit malfunction See F1 59 DTC P0135 P0328 Knock sensor circuit high input See F1 61 DTC P0328 P0335 CKP sensor circuit malfunction See F1 62 DTC P0335 P0443 Evaporative emission control system purge solenoid valve circuit malfunction See F1 64 DTC P0443 P0500 VSS circuit malfunction YES See K2 66 DTC P0500 P0705...

Page 270: ...741 P0742 lililí Torque converter clutch TCC stuck off YES See K2 92 DTC P0742 P0745 Pressure control solenoid valve malfunction YES See K2 94 DTC P0745 P0751 Shift solenoid A malfunction stuck off YES See K2 97 DTC P0751 P0752 Shift solenoid A malfunction stuck on YES See K2 99 DTC P0752 P0753 Shift solenoid A malfunction electrical YES See K2 101 DTC P0753 P0756 Shift solenoid B malfunction stuc...

Page 271: ...772 P0773 I Shift solenoid E malfunction electrical YES See K2 129 DTC P0773 P1170 H02S no inversion See F1 66 DTC P1170 P1250 Pressure regulator control PRC valve circuit malfunction See F1 68 DTC P1250 P1345 CKP sensor circuit malfunction See F1 70 DTC P1345 P1496 EGR valve motor coil 1 open or short See F1 72 DTC P1496 P1497 EGR valve motor coil 2 open or short See F1 74 DTC P1497 P1498 EGR val...

Page 272: ...smatch after engine cranking See F1 89 DTC P1621 P1622 Key ID number mismatch See F1 89 DTC P1622 P1623 l l i l i Code word or key ID number read write error in PCM See F1 90 DTC P1623 P1624 Immobilizer system communication counter 0 See F1 90 DTC P1624 P1627 PCM TCM line communication error See F1 91 DTC P1627 P1631 Generator output voltage signal no electricity See F1 93 DTC P1631 P1633 il Batte...

Page 273: ...cuit between VSS terminal B and PCM terminal 58 Short to ground between VSS terminal B and PCM terminal 58 Open circuit between VSS terminal C and fuse block connector terminal K Open circuit between VSS terminal A and body ground Damaged connectors between VSS and PCM PCM malfunction B FUSE BLOCK K K l n r f i HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE PCM HARNESS SIDE CONNECTOR HARNESS SIDE C...

Page 274: ...erify that VSS connector is disconnected Turn ignition key to ON Engine OFF Check voltage between VSS terminal C harness side and ground Is battery voltage reading B Yes Go to next step No Repair or replace harness then go to Step 9 5 INSPECT VSS GROUND CIRCUIT FOR OPEN Turn ignition key to OFF Verify that VSS connector is disconnected Check for continuity between VSS terminal A harness side and g...

Page 275: ...Drive vehicle under following conditions for 4 5 seconds or more while monitoring PIDs ECT PID 60 C 140 F or above DSW PID ON TR SW PID OFF 1GR PID ON TURBINE PID 1 500 rpm or above Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 10 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER REPAIR PROCEDURE Is there any DTC present Yes G...

Page 276: ... switch terminal G and PCM terminal 6 Short to power between TR switch terminal F and PCM terminal 9 Short to power between TR switch terminal E and PCM terminal 7 Damaged connector between TR switch and PCM PCM malfunction B IGNITION SWITCH TRANSAXLE RANGE SWITCH PCM L o o L O e j W TRANSAXLE RANGE SWITCH i 1 1 G E C ì h H f i t u HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE PCM HARNESS SIDE CON...

Page 277: ...F1 142 INTERMITTENT CONCERN 3 INSPECT TR SWITCH CONNECTOR Turn ignition key OFF Disconnect TR switch connector Inspect for bent terminals of pins using mirror Are TR switch terminals okay Yes Go to next step No Repair terminals or replace TR switch then go to Step7 See K2 31 TRANSAXLE RANGE TR SWITCH REMOVALVINSTALLATION 4 INSPECT TR SWITCH CIRCUIT MALFUNCTION Turn ignition key to ON engine OFF Ac...

Page 278: ...SW R SW and TR SW PIDs using NGS tester Drive vehicle in each range R D S and L for 100 seconds or more under following condition RPM PID 530 rpm or above Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 8 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC inspecti...

Page 279: ...lfunction TR switch malfunction TR switch misadjustment Open circuit between TR switch terminal G and PCM terminal 6 Open circuit between TR switch terminal F and PCM terminal 9 Open circuit between TR switch terminal E and PCM terminal 7 Open circuit between TR switch terminal I and dash harness JB 04 terminals Damaged connectors between TR switch and PCM PCM malfunction TRANSAXLE RANGE SWITCH O ...

Page 280: ...MITTENT CONCERN 3 INSPECT TR SWITCH CIRCUIT Access D SW S SW and L SW PIDs using NGS DSW D range ON Other ranges and all position OFF SSW S range ON Other ranges and all position OFF LSW Yes Adjust TR switch then go to Step 10 See K2 33 TRANSAXLE RANGE TR SWITCH ADJUSTMENT L range ON Other ranges and all position OFF RSW R position ON Other ranges and all positions OFF Are any of following PIDs tu...

Page 281: ...etc Is connection okay Yes Go to next step No Repair or replace connector and or terminals then go to Step 10 9 INSPECT TR SWITCH SIGNAL CIRCUIT FOR OPEN Inspect for continuity between TR switch terminals harness side and PCM terminals harness side D range G to 6 S range F to 9 L range E to 7 R position C to 32 Is there continuity Yes Go to next step No Repair or replace harness then go to next st...

Page 282: ...sensor terminal A and ATX connector terminal E Open circuit between TFT sensor terminal B and ATX connector terminal H Short to ground between TFT sensor terminal B and ATX connector terminal H Open circuit between ATX connector terminal E and PCM terminal 37 Short to ground between ATX connector terminal E and PCM terminal 37 Open circuit between ATX connector terminal H and PCM terminal 91 Damag...

Page 283: ...0 06 V or below Does ATFT V PID change Yes Go to next step No Go to Step 7 5 INSPECT POOR CONNECTION OF TFT SENSOR CONNECTOR CONNECTION Turn ignition key to OFF Remove valve body cover Disconnect TFT sensor connector 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 terminal or replace TFT sensor then g...

Page 284: ...SENSOR REMOVAL INSTALLATION No Go to next step 13 INSPECT TFT SENSOR CIRCUIT FOR SHORT TO GROUND Inspect for continuity between TFT sensor terminals harness side and body ground A and body ground B and body ground Is there any continuity Yes Repair or replace harness then go to Step 15 No Replace TFT sensor then go to Step 15 See K2 35 TRANSAXLE FLUID TEMPERATURE TFT SENSOR REMOVAL INSTALLATION 14...

Page 285: ...sensor voltage Start engine Drive vehicle at 60 km h 37 mph or above for 330 seconds or more Record ATF sensor voltage again Is variation in voltage 0 06V or above Yes Go to Step 4 No Go to next step 3 INSPECT POOR CONNECTOR OF ATX CONNECTOR Turn ignition key to OFF Inspect ATX connector connection Disconnect ATX connector Check for poor connector damaged pulled out terminals corrosion etc Is conn...

Page 286: ...nput turbine speed sensor terminal B and PCM terminal 84 Short to ground between input turbine speed sensor terminal A and PCM terminal 23 Open circuit between input turbine speed sensor terminal B and PCM terminal 84 Open circuit between input turbine speed sensor terminal A and PCM terminal 23 Damaged connectors between input turbine speed sensor and PCM PCM malfunction PCM INPUT TURBINE SPEED S...

Page 287: ... speed sensor terminals part side Is resistance within 250 600 i2between input turbine speed sensor terminals part side See K2 35 INPUT TURBINE SPEED SENSOR INSPECTION Yes Go to next step No Replace input turbine speed sensor then go to Step 9 See K2 35 INPUT TURBINE SPEED SENSOR REMOVAL INSTALLATION 5 INSPECT INPUT TURBINE SPEED SENSOR Remove input turbine speed sensor Is there iron powder stuck ...

Page 288: ...ing NGS tester Drive vehicle with vehicle speed 40 km h 25 mph or above for 0 7 second or more while monitoring PID Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 10 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER REPAIR PROCEDURE Is there any DTC present Yes Go to applicable DTC inspection No Troubleshooting completed K2 81 ...

Page 289: ...utomatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then go to Step 4 See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm up ATX Is ATF level within specification See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Level Inspection Yes Go to next step No Adjust ATF ...

Page 290: ... K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION Yes Replace ATX then go to next step See K2 41 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION No Repair or replace shift valve and return spring then go to next step See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION 9 VERIFY TROUBLESHOOTING OF DTC P0731 COMPLETED Make sure to reconnect all disconnect...

Page 291: ...mation If vehicle is not repaired go to next step No Go to next step 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then ...

Page 292: ... Replace control valve body then go to next step See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION 8 CHECK OPERATION OF EACH VALVE AND EACH SPRING Turn ignition key to OFF Remove control valve body Disassemble control valve body Is each valve operation okay and is return spring okay See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION See ATX ...

Page 293: ...elated Service 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 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Flu...

Page 294: ... Approx 2 173 rpm Yes Go to next step No Replace control valve body then go to next step See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION 8 CHECK OPERATION OF EACH VALVE AND EACH SPRING Turn ignition key to OFF Remove control valve body Disassemble control valve body Is each valve operation okay and is return spring okay See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 ...

Page 295: ...for related Service Information availability Is any related Service 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 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC T...

Page 296: ...ID okay TURBINE PID Approx 2 100 rpm Yes Go to next step No Replace control valve body then go to next step See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION 8 CHECK OPERATION OF EACH VALVE AND EACH SPRING Turn ignition key to OFF Remove control valve body Disassemble control valve body Is each valve operation okay and is return spring okay See K2 46 CONTROL VALVE BODY...

Page 297: ...ake band slipping 3 4 clutch slipping Control valve stuck PCM malfunction Diagnostic procedure STEP INSPECTION ACTION 1 VERIFY RELATED REPAIR INFORMATION AVAILABILITY Check for related Service Information availability Is any related Service 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 2...

Page 298: ...1623 10 98E Yes Replace ATX then go to next step See K2 41 AUTOMATIC TRANSAXLE REMOVAL INSTALLATION No Repair or replace shift valve and return spring then go to next step See K2 46 CONTROL VALVE BODY REMOVAL See K2 46 CONTROL VALVE BODY INSTALLATION See ATX Workshop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0741 COMPLETED Make sure to reconnect all disconnected connectors Clear ...

Page 299: ... repair information If vehicle is not repaired go to next step No Go to next step 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown repl...

Page 300: ...DTC from memory using NGS tester Start engine Warm up engine and ATX Access ATFT 4GR D SW RPM TURBINE VS THOP SHIFT E PID using NGS tester Drive vehicle under following condition with following each throttle conditions while monitoring PIDs ATFT PID 20 C 68 F or above 4GR PID ON D SW PID ON Yes Replace PCM then go to next step See Section F1 RPM PID 450 rpm or above TURBINE PID within 225 4 988 rp...

Page 301: ... ATX connector terminal I and PCM terminal 81 Short to ground between ATX connector terminal D and PCM terminal 44 Short to power between ATX connector terminal D and PCM terminal 44 Open circuit between pressure control solenoid terminal A and ATX connector terminal D Open circuit between ATX connector terminal D and PCM terminal 44 Damaged connector between pressure control solenoid and PCM PCM ...

Page 302: ...ector transaxle case side terminals D and 1 Is resistance within 2 4 7 2 2 See K2 38 SOLENOID VALVES INSPECTION Inspection of Resistance On vehicle Yes Go to Step 7 No Go to next step 5 INSPECT POOR CONNECTION OF PRESSURE CONTROL SOLENOID CONNECTOR Disconnect pressure control solenoid connector Check for poor connection damaged pulled out terminal corrosion etc Is connection okay Yes Go to next st...

Page 303: ...s side and body ground Is there continuity Yes Repair or replace harness then go to next step No Go to next step 1 11 VERIFY TROUBLESHOOTING OF DTC P0745 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Make sure to wait more than 1 second after turning ignition key to ON Is same DTC present Yes Replace PCM then go to next step See Section F1 No G...

Page 304: ...dition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then go to Step 4 See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm up ATX Is ATF level within s...

Page 305: ...ATX Workshop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0751 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT DSW RPM and TURBINE and SHIFT E PIDs using NGS tester Drive the vehicle under the following Yes Replace PCM then go to next step See Section F1 conditions and make sure that gears shift...

Page 306: ...to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then go to Step 4 See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm up ATX I...

Page 307: ...ALVE BODY INSTALLATION See ATX Workshop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0752 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT RPM D SW and TURBINE PIDs using NGS tester Drive the vehicle under the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATFT PID 2...

Page 308: ...terminal 82 Short to power between ATX connector terminal A and PCM terminal 82 Open circuit between shift solenoid A terminal B and ATX connector terminal A Open circuit between ATX connector terminal A and PCM terminal 82 Open circuit between shift solenoid A terminal A and body ground point Damaged connector between shift solenoid A and PCM PCM malfunction ATX CONNECTOR SHIFT SOLENOID A J _____...

Page 309: ...o Go to next step 5 INSPECT POOR CONNECTION OF SHIFT SOLENOID A CONNECTOR Disconnect shift solenoid A connector 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 terminal then go to Step 11 6 INSPECT RESISTANCE Inspect resistance between shift solenoid A terminals A and B part side Is resistance within ...

Page 310: ... DTC P0753 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Access SHIFT A PID using NGS tester Drive vehicle in D range and make sure that gears shift smoothly from 1GR to 4GR Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 12 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER R...

Page 311: ...C TRANSAXLE FLUID ATF REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm up ATX Is ATF level within specification See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Level Inspection Yes Go to next step No Adjust ATF level then go to Step 6 See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Level Inspection 4 INSPECT LINE PRESSURE Start engin...

Page 312: ...er the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATFI PID 20 C 68 F or above D SW PID ON RPM PID 450 rpm or above TURBINE PID within 225 4 988 rpm THOP PID 6 25 or above Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 7 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER REPAIR PROCEDURE Is there...

Page 313: ...on 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 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspect...

Page 314: ...orkshop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0757 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT D SW RPM TURBINE THOP and VS PIDs using NGS tester Drive the vehicle under the following conditionds and make sure that gears shift smoothly from 1GR to 4GR ATFT PID 20 C 68 0 F or above D S...

Page 315: ...hort to power between ATX connector terminal C and PCM terminal 99 Open circuit between shift solenoid B terminal B and ATX connector terminal C Open circuit between ATX connector terminal C and PCM terminal 99 Open circuit between shift solenoid B terminal A and body ground point Damaged connector between shift solenoid B and PCM PCM malfunction ATX CONNECTOR SHIFT SOLENOID B HARNESS SIDE CONNECT...

Page 316: ...No Go to next step 5 INSPECT POOR CONNECTION OF SHIFT SOLENOID B CONNECTOR Disconnect shift solenoid B connector 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 terminal then go to Step 11 6 INSPECT RESISTANCE Inspect resistance between shift solenoid B terminals A and B part side Is resistance within...

Page 317: ...HIFT SOLENOID B COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Access SHIFT B PID using NGS tester Drive vehicle in D range and make sure that gears shift smoothly from 1GR to 4GR Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 12 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AF...

Page 318: ...pair or diagnosis according to available repair information If vehicle is not repaired go to next step No Go to next step 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No ...

Page 319: ...LLATION See ATX Workshop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0761 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT D SW RPM TURBINE and THOP PIDs using NGS tester Drive the vehicle under the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATFT PID 20 C 68 F o...

Page 320: ... Service 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 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF...

Page 321: ...hop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0762 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT D SW RPM TURBINE VS and THOP PIDs using NGS tester Drive the vehicle under the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATFT PID 20 C 68 F or above D SW PID O...

Page 322: ...nal G and PCM terminal 102 Short to power between ATX connector terminal G and PCM terminal 102 Open circuit between shift solenoid C terminal B and ATX connector terminal G Open circuit between ATX connector terminal G and PCM terminal 102 Open circuit between shift solenoid C terminal A and body ground point Damaged connector between shift solenoid C and PCM PCM malfunction ATX CONNECTOR SHIFT S...

Page 323: ... No Go to next step 5 INSPECT POOR CONNECTION OF SHIFT SOLENOID C CONNECTOR Disconnect shift solenoid C connector 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 terminal then goto Step 11 j 6 INSPECT RESISTANCE Inspect resistance between shift solenoid C terminals A and B part side Is resistance with...

Page 324: ... DTC P0763 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Access SHIFT C PID using NGS tester Drive vehicle in D range and make sure that gears shift smoothly from 1GR to 4GR Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 12 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER R...

Page 325: ...on key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then go to Step 4 See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm u...

Page 326: ...shop Manual FN4A EL 1623 10 98E 6 VERIFY TROUBLESHOOTING OF DTC P0766 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT D SW RPM TURBINE VS and THOP PIDs using NGS tester Drive the vehicle under the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATFT PID 20 C 68 F or above D SW PID ...

Page 327: ... REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm up ATX Is ATF level within specification See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Level Inspection Yes Go to next step No Adjust ATF level then go to Step 6 See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Level Inspection 4 INSPECT LINE PRESSURE Start engine Measure line pressu...

Page 328: ...hicle under the following conditions and make sure that gears shift smoothly from 1GR to 4GR ATFT PID 20 C 68 F or above D SW PID ON RPM PID 450 rpm or above TURBINE PID within 225 4 988 rpm Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 7 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER REPAIR PROCEDURE Is there any DTC prese...

Page 329: ...E CAUSE Shift solenoid D malfunction Short to ground between ATX connector terminal B and PCM terminal 27 Short to power between ATX connector terminal B and PCM terminal 27 Open circuit between shift solenoid D terminal A and ATX connector terminal B Open circuit between ATX connector terminal B and PCM terminal 27 Damaged connector between shift solenoid D and PCM PCM malfunction ATX CONNECTOR S...

Page 330: ...Go to next step 5 INSPECT POOR CONNECTION OF SHIFT SOLENOID D CONNECTOR Disconnect shift solenoid D connector 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 terminal then go to Step 11 6 INSPECT RESISTANCE inspect resistance between shift solenoid D terminal A part side and body ground Is resistance ...

Page 331: ...C P0768 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Access SHIFT D PID using NGS tester Drive vehicle in D range and make sure that gears shift smoothly from 1GR to 4GR Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 12 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 61 AFTER REPA...

Page 332: ...ed Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then go to Step 4 See K2 29 AUTOMATIC TRANSAXLE FLUID ATF REPLACEMENT 3 CHECK ATF LEVEL Start engine Warm up ATX Is ATF level within specification S...

Page 333: ...TROUBLESHOOTING OF DTC P0771 COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT D SW RPM TURBINE VS THOP SHIFT A and SHIFT E PIDs using NGS tester Drive the vehicle under the following conditions and make sure that gears shift smoothly from 1GR to 4GR with TCC operation ATFT PID 20 C 68 F or above DSWPID ON RPM P...

Page 334: ... to next step 2 CHECK ATF CONDITION Turn ignition key to OFF Check ATF condition Clear red Normal Milky Water mixed in fluid Reddish brown Deteriorated ATF Is it okay See K2 28 AUTOMATIC TRANSAXLE FLUID ATF INSPECTION Automatic Transaxle Fluid ATF Condition Inspection Yes Go to next step No If ATF color milky or reddish brown replace ATF then go to Step 4 See K2 29 AUTOMATIC TRANSAXLE FLUID ATF RE...

Page 335: ...Clear DTC from memory using NGS tester Start engine Warm up ATX Access ATFT 4GR D SW RPM TURBINE VS THOP and SHIFT E PIDs using NGS tester Drive the vehicle under the following conditions with following each throttle conditions ATFT PID 20 C 68 F or above 4GR PID ON DSWPID ON Yes Replace PCM then go to next step See Section F1 RPM PID 450 rpm or above TURBINE PID within 225 4 988 rpm VS PID below ...

Page 336: ...ft solenoid E malfunction Short to ground between ATX connector terminal F and PCM terminal 1 Short to power between ATX connector terminal F and PCM terminal 1 Open circuit between shift solenoid E terminal A and ATX connector terminal F Open circuit between ATX connector terminal F and PCM terminal 1 Damaged connector between shift solenoid E and PCM PCM malfunction ATX CONNECTOR SHIFT SOLENOID ...

Page 337: ...Go to next step 5 INSPECT POOR CONNECTION OF SHIFT SOLENOID E CONNECTOR Disconnect shift solenoid E connector 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 terminal then go to Step 11 6 INSPECT RESISTANCE Inspect resistance between shift solenoid E terminal A part side and body ground Is resistance ...

Page 338: ... COMPLETED Make sure to reconnect all disconnected connectors Clear DTC from memory using NGS tester Access SHIFT E PID using NGS tester Drive vehicle in D range and make sure that gears shift smoothly from 1GR to 4GR with TCC operation Is same DTC present Yes Replace PCM then go to next step See Section F1 No Go to next step 12 VERIFY AFTER REPAIR PROCEDURE Perform After Repair Procedure See K2 6...

Page 339: ...r ON OFF First gear ON OthersrOFF Inspect following PIDs SHIFT A SHIFT B SHIFT C 2GR Second gear ON OFF Second gear ON Others OFF Inspect following PIDs SHIFT A SHIFT B SHIFT C 3GR Third gear ON OFF Third gear ON Others OFF Inspect following PIDs SHIFT A SHIFT B SHIFT C 4GR Fourth gear ON OFF Fourth gear ON Others OFF Inspect following PIDs SHIFT A SHIFT B SHIFT C ATFT Transaxle fluid temperature ...

Page 340: ...gear 99 Others 0 Inspect shift solenoid C See K2 38 SOLENOID VALVES INSPECTION 102 SHIFT D Shift solenoid D ON OFF N or P position ON Others OFF Inspect shift solenoid D See K2 38 SOLENOID VALVES INSPECTION 27 SHIFT E Shift solenoid E ON OFF Fourth gear at D range ON Others OFF Inspect shift solenoid E See K2 38 SOLENOID VALVES INSPECTION 1 TEN TENterminal in DLC ON OFF Terminal TEN DLC shorted to...

Page 341: ...ous Hot ATF can come out of the opening and badly burn you Before removing the square head plug allow the ATF to cool 3 Connect the SSTs 49 H019 002 49 0378 400B tol the line pressure inspection port Then replace the gauge of the SST 49 0378 400B with 49 B019 901A 4 Start the engine 5 Select the SIMULATION TEST on the NGS See F1 35 ON BOARD DIAGNOSTIC TEST Simulation Test Procedure Caution After t...

Page 342: ...SHIFT D 2 Shift solenoid D ON or OFF X 27 SHIFT E 2 Shift solenoid E ON or OFF X 1 z A simulation test can be performed but inspection is not possible as the line pressure does not change and solenoid valve is barely audible DIAGNOSTIC SUPPORT PROCEDURE 1 Connect the NGS to the DLC 2 Select the DIAGNOSTIC SUPPORT PROCEDURE on the NGS See F1 34 ON BOARD DIAGNOSTIC TEST Diagnostic Support Procedure ...

Page 343: ... See K2 21 MECHANICAL SYSTEM TEST Line Pressure Test Is line pressure okay Yes Go to next step No Adjust accelerator cable as necessary Repair or replace any defective parts according to inspection result 5 Perform the stall test See K2 21 MECHANICAL SYSTEM TEST Stall Test Is stall speed okay Yes Go to next step No Repair or replace any defective parts according to inspection result 6 Inspect the ...

Page 344: ...or pedal is depressed for downshifting 16 Judder upon torque converter clutch TCC operation Vehicle jolts when TCC is engaged 17 Excessive shift shock from N to D or N to R position range Strong shock is felt when shifting from N to D or N to R position range at idle 18 Excessive shift shock is given when upshifting and downshifting Excessive shift shock is felt when depressing accelerator pedal t...

Page 345: ...n torque converter clutch TCC o o o O o O o 0 20 Noise occurs at idle when vehicle is stopped in all positions ranges 21 Noise occurs at idle when vehicle is stopped in D S L ranges or in R position 22 No engine braking in HOLD mode o o O o O o 0 o 0 23 Transaxle overheats o 0 24 Engine stalls when shifted to D S L ranges or in R position o 25 Engine stalls when driving at slow speeds or stopping ...

Page 346: ... is stopped in all positions ranges 21 Noise occurs at idle when vehicle is stopped in D S L ranges or in R position 22 No engine braking in HOLD mode o o o 23 Transaxle overheats o o o O o 24 Engine stalls when shifted to D S L ranges or in R position o o o 25 Engine stalls when driving at slow speeds or stopping o o o 26 HOLD indicator light does not illuminate when HOLD switch is turned to ON 2...

Page 347: ...n 2 Selector lever malfunction 3 Parking mechanism not properly operation 4 Torque converter malfunction Diagnostic procedure STEP INSPECTION ACTION 1 When vehicle Is stopped on a flat paused road and engine is off does vehicle move when pushed in D S ranges or N R positions and brake is released Yes Go to next step No Check for parking mechanism See ATX workshop manual FN4A EL 1623 19 98E 2 Check...

Page 348: ... 0 fi Yes Go to next step No Repair open ground circuit Reconnect PCM 4 Check LINE PID value Is LINE PID value okay Yes Overhaul control valve body and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E If problem remains overhaul transaxle and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E No Repair or replace any defective parts N...

Page 349: ...start The torque converter is malfunction Diagnostic procedure STEP INSPECTION ACTION 1 Does vehicle creep in any range position Yes Go to next step No Inspect or adjust selector lever See K2 56 SELECTOR LEVER REMOVAL INSTALLATION 2 Check the value at the following PID using the NGS tester See F1 25 PCM INSPECTION TPV Is PID value okay Yes Go to next step No Repair or replace any defective parts 3...

Page 350: ...tch operation 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 Go to No 11 Lack loss of power See F1 125 No 11 LACK LOSS OF POWER ACCELERATION CRUISE Does CIS system okay Yes Go to next step No Repair or replace any defective parts 3 Disconnect solenoid connector Does...

Page 351: ...es Vehicle does not shift to 4GR even though accelerator pedal is released in D range at 60 km h 37 mph POSSIBLE CAUSE Basically the TCC does not operate when the fail safe is operating Verify the DTC first If the TCC operates when driving at high speeds only the malfunction improper adjustment is in the HOLD switch circuit or TR switch circuit Caution If the TCC is stuck inspect It In addition in...

Page 352: ...nnect PCM N0 9 ABNORMAL SHIFTING 9 Abnormal shifting DESCRIPTION Shifts incorrectly incorrect shift pattern POSSIBLE CAUSE There is a malfunction in the signal circuit which controls shifting TP sensor input turbine speed sensor vehicle speed sensor the control valve is stuck the accumulator forward or servo apply is stuck or the clutch circuit is stuck 1 Clutch slippage burned Line pressure low S...

Page 353: ...input turbine speed sensor or vehicle speed sensor If the engine speed is high or low regardless normal shifting inspect the tachometer Verify that the output signal of the TP sensor changes linearly NO 12 TORQUE CONVERTER CLUTCH TCC NON OPERATION 12 Torque converter clutch TCC non operation DESCRIPTION TCC does not operate when vehicle reaches TCC operation range POSSIBLE CAUSE Basically the TCC ...

Page 354: ...erhaul transaxle and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E N0 13 NO KICKDOWN 13 No kickdown DESCRIPTION Does not downshift when accelerator pedal is fully depressed within kickdown range POSSIBLE CAUSE If the transaxle does not downshift though shifting is normal the malfunction is in the TP sensor circuit including the sensor GND sensor harness and conn...

Page 355: ...ed for downshifting POSSIBLE CAUSE The malfunction is basically the same as for No 14 Engine flares up or slips when upshifting or downshifting If conditions for No 14 worsen the malfunction will develop to No 15 NO 16 JUDDER UPON TORQUE CONVERTER CLUTCH TCC OPERATION 16 Judder upon torque converter clutch TCC operation DESCRIPTION Vehicle jolts when TCC is engaged POSSIBLE CAUSE Poor TCC engageme...

Page 356: ...fe is operating If no DTC is output the shift shock may worsen due to poor operation of the control valve body or sticking of the clutch 1 Clutch burned N D Forward clutch N R Reverse clutch or low and reverse brake Line pressure low Input turbine speed sensor malfunction TP sensor malfunction Accelerator cable misadjustment Vehicle speed sensor malfunction Control valve body malfunction 2 Poor hy...

Page 357: ...lippage burned 2 4 brake band 3 4 clutch Line pressure low high Shift solenoid E malfunction TP sensor malfunction Shift solenoid A malfunction Vehicle speed sensor malfunction Shift solenoid B malfunction input turbine speed sensor malfunction Shift solenoid C malfunction Transaxle fluid temperature sensor Pressure control solenoid malfunction malfunction Accelerator cable misadjustment Shift sol...

Page 358: ...Diagnostic procedure STEP INSPECTION ACTION 1 Does noise stop when solenoid connector is Yes Go to next step disconnected No Overhaul control valve body and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E If problem remains overhaul transaxle and repair or replace any defective parts See ATX workshop manual FN4A EL 1623 10 98E 2 Check the value at the following PI...

Page 359: ...ring acceleration Engine flares up or slips when shifting Yes Go to symptom 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 defective parts according to inspection result See K2 136 BASIC INSPECTION N0 23 TRANSAXLE OVERHEATS 23 Transaxle overheats DESCRI...

Page 360: ...No 4 Engine stalls See F1 109 NO 4 ENGINE STALLS AFTER START AT IDLE Is engine control system okay Yes Repeat basic inspection and repair or replace any defective parts according to inspection result See K2 136 BASIC INSPECTION No Repair or replace any defective parts according to inspection results N0 25 ENGINE STALLS WHEN DRIVING AT SLOW SPEEDS OR STOPPING 25 Engine stalls when driving at slow s...

Page 361: ...ct PCM Go to next step 4 Check the HOLD indicator light Is 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 replace any defective parts N0 27 HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED TO ON 27 HOLD indicator light illuminates when...

Page 362: ...RONT AND REAR AXLES FEATURES OUTLINE M 2 OUTLINE OF CO NSTRUCTION M 2 SPECIFICATIONS M 2 SERVICE SUPPLEMENTAL SERVICE INFORMATION M 3 DRIVESHAFT M 4 DRIVESHAFT SEDAN 5HB ATX DISASSEMBLY ASSEMBLY M 4 M 1 ...

Page 363: ...ansaxle in the FS engine model Sedan 5HB SPECIFICATIONS Item Engine FP FS Sedan 5HB FS Wagon RF Turbo Transaxle MTX MTX ATX FN4A EL MTX ATX GF4A EL MTX Front axle Bearing type Angular ball bearing Rear axle Bearing type Angular ball bearing Drive shaft Joint type Wheel side Bell joint Differential side Double offset joint Double offset joint Tripod joint Double offset joint Tripod joint Double off...

Page 364: ...CE INFORMATION SUPPLEMENTAL SERVICE INFORMATION Thefollowing changes and or additions have been madesince publication of the Mazda 626 Workshop Manual 1577 10 97D Drive shaft Disassembly Assembly procedures modified M 3 ...

Page 365: ...f disassembly RIGHT SIDE 1 Boot band See M 6 Boot Band Assembly Note 2 Outer ring See M 5 Outer Ring Assembly Note 3 Snap ring 4 Tripod joint 5 Dynamic damper band See M 5 Dynamic Damper Band Assembly Note 6 Dynamic damper See M 5 Dynamic Damper Assembly Note 7 Boot See M 5 Boot Assembly Note 8 ABS sensor rotor See M 5 ABS Sensor Rotor Assembly Note M 4 ...

Page 366: ... 287 7 mm 11 09 11 32 In Dynamic Damper Band Assembly Note 1 Adjust clearance A by turning the adjusting bolt of the SST Clearance A 2 9 mm 0 11 In A 49 T025 001 2 Crimp the band using the SST Verify that clearance B is within the specification Clearance B 2 4 2 8 mm 0 095 0 110 In 3 If clearance B is more than the specification reduce clearance A of the SST and crimp the band again If clearance B...

Page 367: ...does not protrude from the boot band installation area If it does replace the boot band and repeat steps 2 and 3 5 Fill the boot with the repair kit grease 6 Adjust clearance A by turning the adjusting bolt of the SST Clearance A 3 2 mm 0 13 in 7 Crimp the wheel side big boot band using the SST 8 Verify that clearance B is within the specification Clearance B 2 4 2 8 mm 0 095 0 110 in If clearance...

Page 368: ...F CONSTRUCTION N 2 FEATURES N 2 SPECIFICATIONS N 2 SERVICE SUPPLEMENTAL SERVICE INFORMATION N 3 ENGINE SPEED SENSING POWER STEERING N 4 STEERING GEAR AND LINKAGE REMOVAL INSTALLATION N 4 POWER STEERING OIL PUMP RF Turbo REMOVAL INSTALLATION N 5 N 1 ...

Page 369: ...47 in for improved rigidity Simplified power steering system The power steering oil pomp is a vane type equipped with a fluid reservoir and is driven by a gear The operation of the power steering oil pump for RF Turbo engine models is the same as the current PREMACY CP SPECIFICATIONS Item Specification Steering wheel Outer diameter mm in 380 15 0 Lock to lock turns 3 1 Steering gear Type Rack and ...

Page 370: ...ional to the 626 Workshop Manual 1577 10 97D 626 Station Wagon Workshop Manual Supplement 1603 10 97K and 626 626 Station Wagon RF Torbo Workshop Manual Supplement 1614 10 98D Engine speed sensing power steering Steering gear and linkage Removal Installation Power steering oil pump RF Turbo Removal Installation N ...

Page 371: ...n while servicing the vehicle Note On this procedure tightening torque of the steering gear installation bolts and nuts in the figure for the front cross memberhas only been changed from the current models No change has been made for the SSTs and the notes from the current models 1 Remove in the order indicated in the table 2 Install in the reverse order of removal 3 Inspect the front wheel alignm...

Page 372: ...ry 2 Remove the air pipe 3 Remove in the order indicated in the table 4 Install in the reverse order of removal 3 0 4 4 3 0 4 5 22 32 14 17 1 4 1 8 11 13 19 25 1 9 2 6 14 18 14 17 1 4 1 8 11 13 Nm kg1m tt IW 1 Cap 2 Pressure pipe 3 Return hose 4 Power steering oil pump 5 O ring 6 Fluid reservoir 7 Bracket N 5 ...

Page 373: ...BRAKING SYSTEM FEATURES OUTLINE P 2 OUTLINE OF CONSTRUCTION P 2 SPECIFICATIONS P 2 SERVICE SUPPLEMENTAL SERVICE INFORMATION P 3 CONVENTIONAL BRAKE SYSTEM P 4 REAR BRAKE DRUM REMOVAL INSTALLATION P 4 P 1 ...

Page 374: ...al Type Suspended Pedal lever ratio 3 7 Max stroke mm in 116 4 57 Master cylinder Type Tandem with level sensor ABS model Port less Non ABS model Conventional Cylinder inner diameter mm in 23 8 0 937 Front disc brake Type Ventilated disc Cylinder bore mm in 57 15 2 250 Pad dimensions area x thickness mm2 in2 x mm in 4800 7 44 x 10 0 39 5300 8 21 x 10 0 39 Disc plate dimensions outer diameter x thi...

Page 375: ...since publication of the 626 Workshop Manual 1577 10 97D 626 Station Wagon Workshop Manual Supplement 1603 10 97J 626 626 Station Wagon Workshop Manual Supplement 1614 10 98D and 626 626 Station Wagon Workshop Manual Supplement 1168 10 99C Rear brake Drum Removal Installation procedure has been added P 3 ...

Page 376: ...rag 2 Inspect the pedal to floor clearance 3 Inspect the parking brake lever stroke 9 81 12 7 Nm 100 130kgf cm 49 0259 770B N m kgf m ftlbl 1 Hub cap 2 Screw 3 Brake drum 4 Locknut 5 Wheel hub 6 ABS wheel speed sensor 7 Lower return spring 8 Hold pin and hold spring 9 Upper return spring 10 Adjust strut 11 Leading shoe 12 Trailing shoe 13 Adjust spring 14 Adjust lever 15 Parking brake cable 16 Ope...

Page 377: ...UTLINE R 2 OUTLINE OF CONSTRUCTION R 2 FEATURES R 2 SPECIFICATION R 2 FRONT SUSPENSION R 3 SERVICE SUPPLEMENTAL SERVICE INFORMATION R 4 FRONT SUSPENSION R 5 TRANSVERSE MEMBER AND FRONT CROSS MEMBER REMOVAL INSTALLATION R 5 ...

Page 378: ...e Strut Spring type Coil spring Shock absorber type Cylindrical double acting Low pressure gas charged Stabilizer Type Torsion bar Diameter mm in 27 1 06 Front suspension Total mm in Tire 3 4 0 1 2 0 1 6 Rim inner 2 4 0 0 8 0 1 6 toe in degree 0 17 0 23 Wheel Maximum steering angle Inner 38 3 alignment Unloaded 1 Outer 32 30 3 Caster angle 1 52 1 1 44 1 1 42 1 1 39 1 Camber angle 2 0 20 1 0 19 1 0...

Page 379: ...FRONT SUSPENSION iFRONT SUSPENSION STRUCTURAL VIEW 1 Front shock absorber and coil spring 2 Stiffener 3 Front stabilizer 4 Front cross member 5 Transverse member 6 Front lower arm 7 Section A A R 3 ...

Page 380: ...RVICE INFORMATION The following point in this section is additional to the 626 Workshop Manual 1577 10 97D and 626 Station Wagon Workshop Manual Supplement 1603 10 97J Front suspension Transverse member and front cross member Removal Installation R 4 ...

Page 381: ...eering gear installation bolts and nuts in the figure for the front cross member has only been changed from the current models No change has been made for the SSTs and the notes from the current models 1 Remove the front exhaust pipe 2 Remove in the order indicated in the table 3 Install in the reverse order of removal 4 Inspect the front wheel alignment Adjust as necessary N m kgf m ft lbf 7 Lowe...

Page 382: ...TER BATTERY INSPECTION S 20 TRUNKLID S 21 TRUNK LID LOCK REMOVAL INSTALLATION S 21 TRUNK LID ADJUSTMENT S 21 LIFTGATE S 21 LIFTGATE LOCK REMOVAL INSTALLATION S 21 LIFTGATE ADJUSTMENT S 21 BUMPER S 22 FRONT BUMPER REMOVAL INSTALLATION S 22 EXTERIORATTACHMENT S 23 RADIATOR GRILLE REMOVAL INSTALLATION S 23 DASHBOARD AND CONSOLE S 23 CONSOLE REMOVAL INSTALLATION S 23 CONSOLE DISASSEMBLY ASSEMBLY S 24 ...

Page 383: ...ed security Auto lock function and unlock cancel function have been added for the door lock system Improved comfort Armrest box has been adopted for the driver s seat POWER WINDOW SYSTEM OUTLINE The automatic window return function is essentially carried over from that of the current PREMACY CP model except for the structure and resetting in the power window motor _________________________________...

Page 384: ...witch 6 Front power window regulator Driver s side 7 Front power window regulator Passenger s side 8 Rear power window regulator Right side 9 Rear power window regulator Left side 10 Power window subswitch 11 Manual close 12 Manual open 13 Auto 14 Power cut switch 15 Close 16 Open 17 P WIND 30 A fuse 18 P WIND 20 A fuse S 3 ...

Page 385: ...r window motor contains the magnet type pulse generator and limit switch 1 Output axis 2 Print base A 3 Magnet and hole 1C 4 Magnet 5 Gear case 6 Motor 7 Plate 8 Scroll 9 Slider 10 Gear A 11 Gear B C D Speed increasing gear 12 Print base B With hole IC 13 Limit switch 14 Pulse generator S 4 ...

Page 386: ...A 2 Gear B 3 GearC 4 Gear D 5 Magnet 6 Hole IC 7 Motor rotation signal 8 Bottom of door glass 9 Top of door glass Operation When the magnet rotates the hole 1Cdetects the N S magnetic field and outputs it as a voltage pulse For each rotation movement of the door glass approximately 144 mm 5 67 in of the motor 96 pulses are generated The output waveform in the figure above describes the signal wave...

Page 387: ...e printed 5 V GND ______ r 1 1 a 1 Plate 7 Print base A 2 Housing 8 Contact pattern 3 Scroll groove 9 Door glass position detection signal 4 Slider 10 Bottom of door glass 5 Pin 11 Top of door glass 6 Brush For output the limit switch has a built in signal inverting circuit that inverts ON OFF signals at the contact points The output waveform in the figure above describes the signal waveform when ...

Page 388: ... groove 7 Contact points ON Switch output 5 V 8 Non return range Reset operation When the power window regulator is removed or automatic window return function is not operated properly the initial position of the power window motor can be reset by performing the following procedure For details See S 12 DRIVER SIDE POWER WINDOW MOTOR RESETTING When the door glass is raised the slider pin stops at t...

Page 389: ...rporated in the keyless unit in accordance with the addition of an auto lock function The unlock cancel function is used with the trunk lid or liftgate The liftgate or trunk lid has been locked unlocked by the interlock function as well as all doors except during cancellation 5HB sedan SYSTEM WIRING DIAGRAM É 1 Keyless unit 2 Door switch 3 Trunk compartment light switch sedan cargo compartment lig...

Page 390: ... the horizontal position and remove the key The trunk lid or liftgate will not unlock even when the door lock knob transmitter or door key cylinder is operated SEAT OUTLINE The function structure and operation is essentially carried over from that of the current 626 GF and 626 Station Wagon GW models except for the adoption of the box type armrest driver s seat only STRUCTURAL VIEW 1 Armrest box S...

Page 391: ...modified Bumper Removal Installation procedure has been modified Radiator grille Removal Installation procedure has been modified Console Removal Installation procedure has been added Disassembly Assembly procedure has been modified Adjustment procedure has been added Front seat Disassembly Assembly procedure has been modified Troubleshooting Power window system has been added DOOR FRONT DOOR DISA...

Page 392: ... sure to reset the power window motor See S 12 DRIVER SIDE POWER WINDOW MOTOR RESETTING 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly 1 Bolt 2 Power window motor 3 Frame POWER WINDOW MOTOR INSPECTION Driver s Side 1 Remove the power window motor See S 11 FRONT POWER WINDOW REGULATOR DISASSEMBLY ASSEMBLY 2 Apply battery positive voltage to the powe...

Page 393: ...e initial position of a new power window motor which Is separately delivered has been reset Begin again at Step 10 The automatic window return may not operate properly if the following is performed on the front door The power window motor is operated without the door glass properly installed The door glass Is replaced The glass run channel is replaced The power window regulator is removed 1 Remove...

Page 394: ...ng and insert the bushing free of any gaps If the carrier plate is inadvertently raised above the bracket bolts return to Step 6 10 Install the power window regulator to the front door 11 Install the front door glass to the power window regulator 12 Close the power window by operating the power window switch In the event that the automatic window return operates after the window fully closes by au...

Page 395: ...he power window main switch terminals as indicated below 4 Disconnect the power window main switch connector before inspecting for continuity at terminals 1H 2B and 2C If not as specified inspect the parts listed under Action If the parts and wiring harnesses are okay but the system still does not work properly replace the power window main switch Terminal voltage list Reference __________________...

Page 396: ...ion related harness Door glass is not in motion 0 or 5 Except driver s side j 1 Remove the power window main switch 2 Turnthe power cut switch to UNLOCK 3 Inspect for continuity between the power window main switch terminals using an ohmmeter If not as specified replace the power window main switch Passenger s side ___________________________Q Q Continuity Switch position Terminal 1F 1H 1M 1A 1K 1...

Page 397: ...ock knob position Terminal A B c Lock o o Unlock O o UNLOCK LOCK 1 JSL C A D B COMPONENT SIDE CONNECTOR VIEW FROM HARNESS SIDE LIFTGATE LOCK LINK SWITCH INSPECTION Note The liftgate lock link switch is built into the liftgate key cylinder 1 Disconnect the negative battery cable 2 Remove the liftgate trim 3 Disconnect the liftgate lock link switch connector 4 Inspect for continuity between the lift...

Page 398: ...cked 0 B 0 Inspect door lock actuator Inspect liftgate lock actuator Inspect related harness Other 0 D Lock output Door lock actuator Liftgate lock actuator Door lock actuator is locked 0 B 0 Inspect door lock actuator Inspect liftgate lock actuator Inspect related harness Other 0 E F Lock Unlock input Door key cylinder switch Keyless unit Key cylinder had been locked 2 5 5 Inspect key cylinder sw...

Page 399: ...uity to ground Yes Inspect GND 0 Lock input Trunk lid lock link switch Liftgate iock link switch Trunk lid or liftgate is locked inspect for continuity to ground Yes Inspect trunk lid lock link switch Inspect liftgate lock link switch Inspect related harness Trunk lid or liftgate is unlocked inspect for continuity to ground No P Unlock input Trunk lid lock link switch Liftgate lock link switch Tru...

Page 400: ...n B Inspect METER 7 5 A fuse Inspect related harness Ignition switch is at LOCK or ACC position 0 B Power supply ROOM 10 A fuse Under any condition B Inspect ROOM 10 A fuse Inspect related harness C Door open closed Door switch Any door is open door switch is on inspect for continuity to ground Yes Inspect door switch Inspect related harness All doors are closed door switch is off inspect for cont...

Page 401: ...btained if the battery temperature is low make sure the battery has been at 18 C 64 F or more for at least 30 minutes before reinspecting when a measurement value is under the standard voltage Caution Since the battery voltage does not drop fully if the button Is pushed for only 4 seconds or less it can not be properly examined to see whether It is good or bad Always push the button for 5 seconds ...

Page 402: ...Trunk lid key cylinder retainer 3 Trunk lid key cylinder 4 Trunk lid lock actuator 1 Liftgate lock 2 Liftgate key cylinder retainer 3 Liftgate key cylinder 4 Liftgate lock actuator TRUNKLID ADJUSTMENT 1 Loosen the trunk lid installation nuts 2 Reposition the trunk lid as specified Clearance a 3 0 5 0 mm 0 12 0 19 in b 0 5 1 5 mm 0 019 0 059 in c 4 5 9 5 mm 0 18 0 37 In LIFTGATE ADJUSTMENT 1 Loosen...

Page 403: ...oval 7 Adjust the front fog light aiming if equipped with front fog lights See T 17 FRONT FOG LIGHT AIMING 16 22 1 6 2 3 12 16 Protector Removal Note 1 Apply protective tape to the front bumper to protect it from damage 2 Disengage clips A using a tape wrapped flathead screwdriver 3 Pull the protector indicated by the arrow and disengage hooks B from the front bumper C U P A HOOK B 1 Protector See...

Page 404: ...tor grille forward then disengage clips A from the front bumper SCREW C U P A 4 Install in the reverse order of removal CONSOLE REMOVAL INSTALLATION 1 Shift the selector lever to L range ATX 2 Remove the selector lever knob ATX 3 Remove the shift knob MTX 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 6 Adjust the console See S 24 CONSOLE ADJUSTMENT TYPE 1 S...

Page 405: ...2 Console lid lock 3 Console inner lid 4 Console lid stopper 5 Console lid 6 Ashtray 7 Bracket CONSOLE ADJUSTMENT Caution Take care to install the console and the center panel so that there is not any Interference which may cause noise 1 Loosen screws A 2 Slide the console indicated shown by the arrow and measure the gap between the console and the dashboard Clearance a 2 0 8 0 mm 0 08 0 31 in DAS...

Page 406: ...e 1 Remove the driver side side air bag module See Section T 2 Disassemble in the order indicated in the table 3 Assemble in the reverse order of disassembly 1 Armrest 2 Headrest 3 Pole guide 4 Seat back trim 5 Seat back pad 6 Seat back frame 7 Seat cushion trim 8 Seat cushion pad 9 Seat cushion frame 10 Seat warmer unit 11 Recliner dial 12 Tilt dial 13 Side cover No 1 14 Lower cover 15 Recliner k...

Page 407: ...witch power supply wiring harnesses Wiring harness between power window main switch and power window motor Power window main switch Power window motor Each power window motor wire installation point Each window s installation point on its carrier plate Each power window regulator installation point on each door Repair or replace the problem area then go to Step4 2 Does each window go up and down i...

Page 408: ...hile it is going up in automatic mode Yes Go to Step 1 of troubleshooting index No 3 No Go to next step 2 Open driver side front window completely Take a hammer and hold it against the inside of the top of the window frame so that the window will hit its handle when it is closed Close the window using automatic mode When the window hits the hammer handle does it immediately reverse and go down to ...

Page 409: ...d undamaged STEP INSPECTION ACTION 1 CHECK TO SEE WHETHER POWER WINDOW MAIN SWITCH ENTER FAIL SAFE MODE OR NOT Did driver side front window go up or down in automatic mode Yes Recheck malfunction symptoms No Go to next step Power window main switch may enter fail safe mode 2 CHECK TO SEE WHETHER PROBLEM IS WITH LIMIT SWITCH SIGNAL OR GROUND SIGNAL BETWEEN POWER WINDOW MAIN SWITCH IN DRIVER SIDE FR...

Page 410: ...C ground signal Is voltage approximately 12 V Yes Repair wiring harness between power window main switch and driver side front power window motor then go to Step 15 No Replace power window main switch open or short to B in power window main switch 6 CHECK TO SEE WHETHER PROBLEM IS WITH PULSE GENERATOR SIGNAL OR 5 V SIGNAL BETWEEN POWER WINDOW MAIN SWITCH AND DRIVER SIDE FRONT POWER WINDOE MOTOR Te...

Page 411: ...ition switch to ON position Measure voltage at power window main switch connector terminal 2D pulse generator signal Is voltage approximately 12 V Yes Repair wiring harness between power window main switch and front driver side power window motor then go to Step 15 Replace power window main switch open or short to B ground in power window main switch then go to Step 15 No Go to next step 11 CHECK ...

Page 412: ...TOMS DO NOT RECUR AFTER REPAIR Reset the driver side front window motor See S 12 DRIVER SIDE POWER WINDOW MOTOR RESb I IING Did malfunction disappear Yes Troubleshooting completed Explain repairs to customer No Recheck malfunction symptoms then repeat from Step 1 if malfunction recurs N O 2 AUTOMATIC WINDOW RETURN FUNCTION DOES NOT WORK 2 Automatic window return function does not work DESCRIPTION ...

Page 413: ...DE FRONT WINDOW MOTOR IS MEMORY Reset the driver side window motor See S 12 DRIVER SIDE POWER WINDOW MOTOR RESETTING Did malfunction disappear Yes Troubleshooting completed Explain to customerthat adjustment of auto reverserange was bad No Go to next step 2 INSPECT FOR FOREIGN OBJECT IN DRIVER SIDE FRONT WINDOW Is there a foreign object in driver side front window Yes Remove the object No Go to ne...

Page 414: ...OWER WINDOW MAIN SWITCH AND DRIVER SIDE FRONT POWER WINDOW MOTOR OR POWER WINDOW MAIN SWITCH Yes Repair wiring harness between power window main switch and driver side front power window motor then go to Step 9 Turn ignition switch to LOCK position Disconnect power window main switch Is there continuity between power window main switch connector terminal 2B limit switch signal and ground No Replac...

Page 415: ...HOOTING KEYLESS ENTRY SYSTEM TROUBLESHOOTING KEYLESS ENTRY SYSTEM FOREWORD Go to troubleshooting after identifying the specific malfunction by doing a keyless entry system preliminary inspection Flowchart S 34 ...

Page 416: ...hicle Make sure the ignition key is either in the LOCK position or removed 1 Does keyless entry system work Yes Explain the following to the customer Keyless entry system does not work when ignition switch is in ON position Keyless entry system does not work from excessive distances more than 2 5 m 8 2 ft away from center of vehicle No Go to Q4 Q4 Check location where customer uses keyless entry s...

Page 417: ... transmitter in non interference area If system operates Area of operation is bad Explain effect of outside interference on transmitter to customer If system does not operate Go to next step No Go to next step 4 Are any of the following after market electrical parts on the vehicle Cellular phone Radio wave equipment Remote engine starter TV etc Yes Disconnect after market electrical part connector...

Page 418: ...TROUBLESHOOTING KEYLESS ENTRY SYSTEM ON BOARD DIAGNOSTIC FUNCTION S 37 ...

Page 419: ...ring harness between keyless unit and cargo compartment light switch Malfunction in keyless unit GND signal circuit Malfunction in wiring harness between keyless unit and ground Malfunction in keyless unit door lock unlock signal circuit Keyless unit malfunction Malfunction in wiring harness between keyless unit and door lock timer unit ii Diagnostic procedure i When performing an asterisked troub...

Page 420: ... installed securely Yes Go to next step No Install cargo compartment light switch securely then go back to Step 5 of keyless entry system preliminary inspection 9 INSPECT FOR DTC 04 IN INSTRUMENT CLUSTER Inspect door switch using instrument cluster input output check mode See T 26 INSTRUMENT CLUSTER INSPECTION Does DTC 04 function properly Yes Go to next step No Repair door switch system using DTC...

Page 421: ...n reoccurs NO 2 TRANSMITTER ID CODE CANNOT BE REPROGRAMMED 2 Transmitter ID code cannot be reprogrammed DESCRIPTION CPU s transmitter ID code reprogram function does not work POSSIBLE CAUSE Malfunction in transmission circuit Transmitter battery transmitter keyless unit bracket keyless unit bracket ground screw or keyless unit malfunction Diagnostic procedure STEP INSPECTION ACTION 1 INSPECT TRANS...

Page 422: ...ystem operate properly Yes Replace transmitter battery then go to Step 8 No Go to next step 7 CHECK TO SEE WHETHER MALFUNCTION IS IN TRANSMITTER OR KEYLESS UNIT Reprogram transmitter ID codes by using another known good transmitter Does keyless entry system operate okay Yes Replace transmitter and reprogram transmitter ID code then go to next step No Replace keyless unit and reprogram transmitter ...

Page 423: ...ION T MTERIOR LIGHTING SYSTEM T DOOR SWITCH REMOVAL INSTALLATION T GLOVE COMPARTMENT LIGHT SWITCH REMOVAL INSTALLATION GLOVE COMPARTMENT LIGHT SWITCH INSPECTION WIPER AND WASHER HEADLIGHT CLEANER NOZZLE AD JU STM EN T HEADLIGHT CLEANER SWITCH INSPECTION HEADLIGHT CLEANER RELAY REMOVAL INSTALLATION HEADLIGHT CLEANER RELAY INSPECTION WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER DISASSEMBLY ASSEMB...

Page 424: ... 101 DTC 9 1 T 101 TROUBLESHOOTING T 104 TROUBLESHOOTING INDEX T 104 No 1 AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE T 104 No 2 AIR BAG SYSTEM WARNING LIGHT IS ILLUMINATED ALL THE T IM E T 106 No 3 PASSENGER SIDE AIR BAG CUT OFF INDICATOR LIGHT DOES NOT DIM T 108 No 4 PASSENGER SIDE AIR BAG CUT OFF INDICATOR IS ILLUMINATED ALL THE TIM E T 110 T 2 ...

Page 425: ...l Supplement 1603 10 97J FEATURES Improved serviceability DTCs 06 22 23 24 and 25 of input output check mode in the instrument cluster have been added The side air bag system and passenger side air bag cut off function have been changed The circuit of running light system has been changed Improved marketability The glove compartment light has been added The antenna type of sedan and 5HB have been ...

Page 426: ...dition New 626 323 BJ Headlight high beam on Low beam on Low beam off System Wiring Diagram 10 Headlight high relay 11 TNS relay 12 Parking light taillight license plate light 13 Instrument cluster 14 Headlight switch 15 Headlight 16 Flash to pass 17 To front fog light relay 1 Running light unit 2 Relay A 3 Relay B 4 FP FS FS Hi power 5 Headlight relay 6 Headlight low beam 7 Headlight high beam 8 ...

Page 427: ...______________________EXTERIOR LIGHTING SYSTEM INTERIOR LIGHTNG SYSTEM OUTLINE The glove compartment light has been added STRUCTURAL VIEW D 1 Glove compartment light T 5 ...

Page 428: ... tripmeter No Warning and indicator light Note 7 HOLD indicator light ATX only 8 Passenger side air bag cut off indicator light 9 Rear fog light indicator light 10 ABS warning light 11 Oil pressure warning light 12 Brake system warning light 13 Sedimentor warning light RF Turbo 14 Air bag system warning light 15 TSC indicator light 16 TSC OFF light 17 Washer fluid level warning light 18 Front fog ...

Page 429: ... Tachometer Red zone rpm RF Turbo 5000 6000 FP FS FS Hi power 6500 3000 Input signal source PCM Input signal 4 pulses two engine rotations Rated voltage V DC 12 Fuel gauge Meter type Cross coil type Reset to zero type Rated voltage V DC 12 Water temperature gauge Meter type Cross coil type Medium range stabilized type Rated voltage V DC 12 Display LCD Indication digits 6 digits Odometer Characteri...

Page 430: ...icator light 18 Front fog light indicator light 19 Rear fog light indicator light 20 Key reminder switch 21 Ignition key illumination 22 Door lock timer unit 23 Door lock link switch 24 Interior light 25 Front fog light relay 26 Front fog light 27 Front fog light switch 28 Rear fog light relay 29 Rear fog light 30 Vehicle speedometer sensor 31 Fuel gauge sender unit 32 Water temperature sender uni...

Page 431: ... light 52 High beam indicator light 53 Hazard warning switch 54 Flasher unit 55 Turn switch 56 TNS relay 57 Headlight relay 58 Headlight switch 59 Headlight left 60 Headlight right 61 Climate control unit 62 Rear window defroster switch 63 Rear window defroster switch illumination 64 Rear window defroster relay 65 Filament 66 Transaxle range switch 67 Cruise control module 68 Without TCS 69 With T...

Page 432: ... with ABS PCM ATX Station wagon Vehicle speedometer sensor Without ABS ABS HU CM With ABS Vehicle speedometer sensor 11 X X PCM 22 X Fuel gauge sender unit 24 X Water temperature sender unit 29 X X Rear fog light switch 31 X X Key reminder switch 40 X X Front fog light relay Individual part check x Applied Not applied DTC New 626 Current 626 GF Parts sending Input signal New 626 Current 626 GF 12 ...

Page 433: ...NT SYSTEM IMMOBILIZER SYSTEM OUTLINE The construction and operation is the same as that of the current DEMIO 121 DEMIO DW model STRUCTURAL VIEW 4 Key transponder 5 PCM 1 Coil 2 Immobilizer unit 3 Security light T 11 ...

Page 434: ... left 8 Turn light right 9 Trunk lid lock link switch liftgate lock link switch 10 Lock 11 Unlock 12 Keyless unit 13 Driver s door key cylinder switch 14 Passenger s door key cylinder switch 15 Liftgate key cylinder switch 16 Door lock timer unit 17 Driver s door lock link switch 18 Instrument cluster 19 Security light 20 Door switch 21 Passenger s door lock link switch 22 Left side rear door lock...

Page 435: ...S unit Side air bag sensor Same as the current 323 BJ model Driver side air bag module Passenger side air bag module Same as the current 626 GF model Side air bag module Same as the current 323 BJ model Clock spring Air bag system warning light Pre tensioner seat belt Same as the current 626 GF model Passenger side air bag cut off function Same as the current 323 BJ model Deployment authorization ...

Page 436: ...le 2 Passenger side air bag module 3 Clock spring 4 Driver side side air bag module 5 Passenger side side air bag module 6 SAS unit 7 Driver side side air bag sensor SYSTEM COMPONENT Available combinations of the air bag system components are shown below x Applied Not applied Component A B C D E Pre tensioner seat belt X x X X X Driver side air bag module X X X X X Passenger side air bag module X ...

Page 437: ...Removal Installation procedure added Inspection procedure added Headlight cleaner nozzle Adjustment procedure modified Instrument cluster Disassembly assembly procedure modified Inspection procedure modified Input output check mode procedure modified Fuel gauge sender unit Inspection procedure modified Horn Removal Installation procedure modified Horn relay Removal Installation procedure modified ...

Page 438: ...f not as specified replace the ignition switch O O Continuity Ignition key position Terminal E F D C B A LOCK ACC o o ON r i r o vj KJ START J r KJ U D ACCESSORY SOCKET INSPECTION 1 Remove the accessory socket 2 Inspect for continuity between the accessory socket terminals A and B using an ohmmeter as shown in the figure If not as specified replace the accessory socket n C L I l I L E c A F D B CO...

Page 439: ...n the front fog light on 8 Adjust the brightness border line by turning the adjusting screw as shown in the figure Loosen the screws first then tighten 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 front fog lights to become misaligned FRONT FOG LIGHT BULB REMOVAL INSTALLATION 1 Remove the front fog ...

Page 440: ...nnect the negative battery cable 2 Remove the trunk lid trim 3 Remove the rear finisher 4 Remove in the order indicated in the table 5 Install in the reverse order of removal 1 Nut 2 Inboard combination light 3 Gasket 4 Connector 5 Socket 6 Back up light bulb 7 Rear fog light bulb T 18 ...

Page 441: ...SIDE Terminal Signal Connected to Test condition Voltage V Continuity Action A Power supply Hazard warning switch Hazard warning switch on Alternates B and 0 Inspect HAZARD 15 A fuse Inspect METER 7 5 A fuse Inspect hazard warning switch Inspect related harness Hazard warning switch off Ignition switch at ON position B Ignition switch at LOCK or ACC position Below 1 0 B Flasher unit output Hazard ...

Page 442: ...h dimmer at HI position Below 1 0 Flash to pass on Below 1 0 1B TNS operation Parking light Taillight License plate light Ignition switch at ON position B Ignition switch at LOCK or ACC position Headlight switch light at TNS or headlight position B Headlight switch light at OFF position Below 1 0 1C Headlight high beam on off Headlight switch Headlight switch dimmer at LO position inspect for cont...

Page 443: ... cooling fan relay 4 Remove as indicated in the table 5 Install in the reverse order of removal TNS RELAY INSPECTION 1 Remove the TNS relay 2 Inspect for continuity between the TNS relay terminals using an ohmmeter If not as specified replace the TNS relay Q Q Continuity TNS relay removal note 1 Insert a tape wrapped flathead screwdriver into the dented portion of the TNS relay Step Terminal A E C...

Page 444: ...ay terminals using an ohmmeter If not as specified replace the headlight relay O O Continuity Step Terminal A E C D 1 0 o 2 B GND O o E I I COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL SIDE FRONT FOG LIGHT RELAY REMOVAL INSTALLATION FP FS FS Hi power 1 Remove the negative battery cable 2 Remove the main fuse block cover 3 Remove as indicated in the table 4 Install in the reverse order of removal Fr...

Page 445: ...___________________Q Q Continuity Step Terminal A E C D 1 0 o 2 B GND o o E X A c D COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL SIDE REAR FOG LIGHT RELAY INSPECTION 1 Remove the bracket and pull it toward you 2 Inspect for continuity between the rear fog light relay terminals using an ohmmeter If not as specified replace the rear fog light relay O O Continuity Step Terminal A E C D 1 0 o 2 B GND o...

Page 446: ... 3 Glove compartment light bulb GLOVE COMPARTMENT LIGHT SWITCH INSPECTION 1 Remove the glove compartment light switch 2 Inspect for continuity between the glove compartment light switch terminals using an ohmmeter If not as specified replace the glove compartment light switch O O Continuity Switch position Terminal A B Pressed Released O 0 m n a i i B A COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL ...

Page 447: ...elay is damaged easily do not remove the relay from the bracket unless replacement is necessary Always perform an inspection of the headlight cleaner relay before removal 1 Disconnect the negative battery cable 2 Remove the bracket 3 Disconnect the headlight cleaner relay connector 4 Remove the headlight cleaner relay FP FS BRACKET FS HI POWER HEADLIGHT CLEANER RELAY CONNECTOR RF TURBO HEADLIGHT C...

Page 448: ...ange km h 20 20 24 40 40 44 60 60 64 80 80 84 100 100 105 120 120 126 140 140 146 R H D Speedometer tester indication km h Allowable range km h 20 18 22 40 38 42 60 58 62 80 78 82 100 97 103 120 117 123 140 137 143 Speedometer tester Indication mph Allowable range mph 20 20 22 40 40 43 60 60 63 80 80 84 3 Verify that fluctuation of the speedometer needle is within the allowable range If the speedo...

Page 449: ...1 RF Turbo Tester indication rpm Allowable range rpm 1 000 964 1 060 2 000 1 982 2 112 3 000 3 000 3 162 4 000 4 017 4 213 5 000 5 036 5 264 6 000 6 054 6 314 Fuel Gauge 1 Inspect the fuel gauge by setting 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 24 FUEL GAUGE SENDER UNIT INSPECTION 1 Rem...

Page 450: ... indicated in the table 5 Install in the reverse order of removal MAIN FUSE BLOCK HORN RELAY INSPECTION 1 Remove the horn relay 2 Inspect for continuity between the horn relay terminals using an ohmmeter If not as specified replace the horn relay O O Continuity Step Terminal A E D C 1 O o 2 B GND o 0 COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL SIDE Horn relay See T 28 Horn relay removal note Horn ...

Page 451: ...tch at LOCK or ACC Below 1 0 D Illumination Headlight switch Headlight switch at TNS B Inspect TAIL 10 A fuse Inspect headlight switch Inspect related harness Headlight switch at OFF Below 1 0 E Information display ground GND Under any condition inspect for continuity to ground Yes Inspect GND F Fuel Fuel gauge sender unit See T 30 F terminal inspection Inspect fuel gauge sender unit Inspect relat...

Page 452: ...n the information display 3 Apply the speed of the vehicle to the following calculation in order to calculate the cycle T and verify that the cycle T does not vary largely from the cycle on the screen of oscilloscope Calculation T ms 1413 T 1 cycle V speed V km h 4 Verify that the wave pattern is continuous and output voltage is constant B T ms O terminal inspection 1 Measurer the wave pattern of ...

Page 453: ... light Rear window defroster 18 Ignition key cylinder illumination Ignition key cylinder illumination 20 Rear window defroster relay Rear window defroster 21 Door lock timer unit Theft deterrent system Power door lock system 22 Fuel gauge sender unit Fuel gauge 23 Fuel gauge Fuel gauge 24 Water temperature sender unit Water temperature gauge 25 Water temperature gauge Water temperature gauge 26 LC...

Page 454: ...WARNING AND INDICATOR SYSTEM O p e ra tin g O rd e r T 32 ...

Page 455: ... then go to next step r r i_ i I I Measure voltage at instrument cluster terminal 11 Is voltage 0 V If as specified replace instrument cluster If not as specified Inspect following parts Door switch Wiring harness Instrument cluster door switch 2 Open passenger side door Door switch on C i n Close passenger side door then go to next step r r i_ i I 1 Measure voltage at instrument cluster terminal ...

Page 456: ... off signal INSTRUMENT CLUSTER CONNECTOR 3S 3Q 3 0 3M 3K 31 3G 3E 3C 3A 3T 3R 3P 3N 3L 3J 3H 3F 3D 3B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE Diagnostic procedure STEP INSPECTION INDICATION ACTION 1 Turn driver side door lock knob to lock position Door lock link switch to lock position C i n Go to next step r r LI I I Measure voltage at instrument cluster terminal 3F Is voltage 0 V If as spe...

Page 457: ...again Outer handle switch off O n Measure voltage at terminal 3M of outer handle switch Is voltage 5 V If as specified replace instrument cluster If not as specified Inspect following parts Outer handle switch Wiring harness Instrument cluster outer handle switch r r i_ i I r Input signal to instrument cluster Is okay DTC 07 Rear window defroster switch on off signal INSTRUMENT CLUSTER CONNECTOR 3...

Page 458: ...B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SI DE Diagnostic procedure STEP INSPECTION INDICATION ACTION 1 Turn headlight switch to TNS position TNS relay on C i n Go to next step r r L i 1 1 Measure voltage at instrument cluster terminal 1E Is voltage B If as specified replace instrument cluster If not as specified inspect following parts TNS relay Wiring harness Battery TNS relay instrument clust...

Page 459: ... terminal 3Q Is voltage B If as specified replace instrument cluster If not as specified inspect following parts Headlight switch Wiring harness Instrument cluster headlight switch GND r r i_i I r Input signal to instrument cluster is okay DTC 10 Vehicle speed input signal INSPECTION INDICATION ACTION Rotate drive wheels using chassis roller I J n Input signal to instrument cluster is okay r r U I...

Page 460: ...turns to 60 km h or 60 MPH Speedometer is okay Other than stated above Replace instrument cluster r L I I DTC 13 Operation signal to tachometer INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 13 C i C i Tachometer needle moves full scale then returns to 3000 rpm Tachometer is okay Other than stated above Replace instrument cluster r L I DTC 14 Operation signal to buzz...

Page 461: ...ng DTC 16 G n Turns on and off Fuel level warning light turns on and off three times Fuel level warning light is okay Other than stated above Inspect bulb for bum out or looseness If there is malfunction replace or reinstall bulb as necessary If bulb is okay replace instrument cluster DTC 17 Operation signal to rear window defroster indicator light INSPECTION INDICATION SITUATION ACTION Wait for 2...

Page 462: ...window defrostor relay on off signal INSTRUMENT CLUSTER CONNECTOR 3S 3Q 30 3M 3K 3I 3G 3E 3C 3A 3T 3R 3P 3N 3L 3J 3H 3F 3D 3B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE Diagnostic procedure INSPECTION INDICATION SITUATION ACTION Walt for 2 seconds after selecting DTC 20 Rear window defroster relay turns on and off three times Rear window defroster relay is okay Other than stated above I J I I T...

Page 463: ...ignal INSTRUMENT CLUSTER CONNECTOR 3S 3Q 3 0 3M 3K 3I 3G 3E 3C 3A 3T 3R 3P 3N 3L 3J 3H 3F 3D 3B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE Diagnostic procedure STEP INSPECTION INDICATION ACTION 1 Select DTC 22 with fuel gauge sender unit connector disconnected II I Il II 5 n i i___ i j Go to next step Other than stated above Replace instrument cluster 2 Connect instrument cluster terminal 3C to...

Page 464: ...on signal to fuel gauge INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 23 Ü Ü Fuel gauge indicates in following order for every 2 seconds F 1 2 E F fixed Fuel gauge is okay Other than stated above Replace instrument cluster n n j j Replace instrument cluster DTC 24 Water temperature signal INSTRUMENT CLUSTER CONNECTOR 3S 3Q 30 3M 3K 3I 3G 3E 3C 3A 3T 3R 3P 3N 3L 3J 3...

Page 465: ...ment cluster 5 Using SST Fuel And Thermometer checker or resistor input 100 2to instrument cluster terminal 3E H i i f i i I i l Ï i l l i l U _ I Inspect water temperature sender unit Other than stated above Replace instrument cluster DTC 25 Operation signal to water temperature gauge INSPECTION INDICATION SITUATION ACTION Wait for 2 seconds after selecting DTC 25 C l0 Water temperature gauge ind...

Page 466: ...RUMENT CLUSTER CONNECTOR 1Q 1 0 1 M 1 K 11 1G 1 E 1C 1 A 1 R 1P 1 N 1 L 1J 1H 1F 1 D 1B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE Diagnostic procedure STEP INSPECTION INDICATION ACTION 1 1 Verify that indication is off 2 Push and hold rear fog light switch Rear fog light switch is on I J n Go to next step r r U I I Measure voltage at instrument cluster terminal 3T Is voltage 5 V If as specifie...

Page 467: ...k Key reminder switch off Ci n Measure voltage at instrument cluster terminal 2J Is voltage OV If as specified replace instrument cluster If not as specified inspect following parts Key reminder switch Wiring harness Key reminder switch instrument cluster r r i_ i i i Input signal to instrument cluster is okay DTC 40 Front fog light relay on off signal INSTRUMENT CLUSTER CONNECTOR 2 0 2M 2K 2 I 2G...

Page 468: ...ght relay off r r L i 1 I Input signals to instrument cluster are okay ü n Measure voltage at instrument cluster terminal 2N Is voltage 0 V If as specified replace instrument cluster If not as specified inspect following parts Front fog light switch Wiring harness Instrument cluster front fog light relay T 46 ...

Page 469: ...inal Signal Connection to Test condition Voltage V Action Ignition switch at ON position B Inspect ignition switch ENGINE 10 A fuse Inspect related harness 1A IG1 ENGINE 10 A fuse Ignition switch at LOCK or ACC position Below 1 0 1B Power supply ROOM 10 A fuse Under any condition B ROOM 10 A fuse Ignition switch ON position Turn switch on Alternates 0 and B Turn switch off Below 1 0 Inspect turn s...

Page 470: ...spect theft deterrent horn relay Inspect related harness Theft deterrent system alarm 1 Active Alternates 0 and B 2D Key reminder switch on off Key reminder switch Key reminder switch on B Inspect key reminder switch Inspect related harness Key reminder switch off 0 Below 1 0 2E 2F Lock unlock Door lock timer unit Driver s door lock link switch Driver s door lock link switch locked inspect for con...

Page 471: ...t driver s or passenger s door key cylinder switch Inspect keyless unit Inspect related harness Driver s or passenger s door or liftgate unlocked with key or transmitter Below 1 0 Other 5 2P Trank compartment light switch Cargo compartment light switch on off Trank compartment light switch Cargo compartment light switch Trank compartment light switch Cargo compartment light switch on Below 1 0 Ins...

Page 472: ...y ROOM 10 A fuse Under any condition B ROOM 10 A fuse Ignition switch ON position Turn switch on Alternates 0 and B Turn switch off Below 1 0 Inspect turn switch 1C Flasher input Turn switch Hazard warning switch Flasher unit Hazard warning switch on Alternates 0 and B Inspect hazard warning switch Inspect flasher unit Inspect related harness Hazard warning switch off Below 1 0 Theft deterrent sys...

Page 473: ...switch Passenger s and rear door lock link switch locked inspect for continuity to ground No Inspect passenger s or rear door lock link switch Inspect related harness Passenger s or rear door lock link switch unlocked inspect for continuity to ground Yes 2N Bonnet open closed Bonnet switch Bonnet switch on inspect for continuity to ground Yes Inspect bonnet switch Inspect related harness Bonnet sw...

Page 474: ...ness Security light off B 2R Door open closed Door switch Any door open inspect for continuity to ground Yes Inspect door switch Inspect related harness All doors closed inspect for continuity to ground No 2S Theft deterrent relay on off Theft deterrent relay Theft deterrent system alarm 1 Active Below 1 0 Inspect theft deterrent relay Inspect related harnass Theft deterrent system alarm 1 Other B...

Page 475: ...er indicated in the table 2 Assemble in the reverse order of disassembly 1 Drain hose 2 Bracket 3 Harness 4 Ground plate 5 O ring 6 Rod insulator 7 Motor POWER ANTENNA INSPECTION Sedan 5HB 1 Remove the trunk side trim 2 Disconnect the power antenna connector 3 Connect ground to a bare metal part of vehicle and terminal D of the power antenna 4 Connect battery positive voltage to the following term...

Page 476: ...nd 3 Audio power switch is on 4 To turn on the radio press AM FM button 5 To turn off the radio turn the audio power switch off then immediately insert the rack into the power antenna REAR NOISE FILTER REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the lower panel 3 Remove in the order indicated in the table 4 Install in the reverse order of removal L H D R H D NOISE FILTER ...

Page 477: ...ify that there is no continuity between the front antenna feeder terminals A and B using an ohmmeter 5 Inspect for continuity between the front antenna feeder terminals using an ohmmeter If not as specified replace the instrument panel harness Q Q Continuity Step Terminal A B c D 1 o 2 o o REAR ANTENNA FEEDER REMOVAL INSTALLATION Note The rear antenna feeder is fixed to the room harness 1 Disconne...

Page 478: ...ich may result in serious injury or death in the event of an accident Do not disassemble any air bag system components Wiring Harness Repair Incorrectly repairing an air bag system wiring harness can accidentally deploy the air bag module or pre tensioner seat belt which can cause serious Injury If a problem is found in the system wiring replace the wiring harness Do not try to repair It Air Bag M...

Page 479: ...r vehicles with a single point sensor once an air bag module is deployed due to an accident or other causes the SAS unit must be replaced with a new one even if the used one does not have any external signs of damage The used SAS unit may have been damaged internally which may cause improper operation resulting in major injuries or even death The used single point SAS unit cannot be bench checked ...

Page 480: ...can be reused SIDE AIR BAG SENSOR REMOVAIVINSTALLATION 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 before handling the side air bag sensor See T 58 SERVICE WARNINGS 1 Turn the ignition switch to LOCK position 2 Disconnect the negative battery cable and wait for more than 1 mi...

Page 481: ... more than 1 minute 3 Remove the side walls 4 Remove in 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 seconds and then goes off If the air bag system warning light does not operate in the manner described above there are malfunctions in the system In...

Page 482: ...the applicable 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 after present and or past malfunctions have been repaired be sure to perform past malfunction display cancellation to prevent repair of malfunctions that have already been repaired T 60 ...

Page 483: ...ion switch to LOCK position Disconnect negative battery cable Connect all SAS unit connectors Conned clock spring connector Connect passenger side air bag module connector Connect driver and passenger side side air bag module connectors Vehicle with side air bag Connect driver and passenger side pre tensioner seal belt connector Vehicle with pre tensioner seat belt Connect negative battery cable T...

Page 484: ...steps alternately three times each at 0 5 1 5 seconds intervals 1 Use a jumper wire to short the DLC terminal SCN to body GND 2 Disconnect the jumper wire from body GND t t OPEN SCN SHORT 1 2 r 3 t 0 5 1 5 SECONDS 4 If the DTCs are displayed wait until they disappear 5 Using a jumper wire short the DLC terminal SCN to body GND to verify that the DTCs of the past malfunction are not displayed If th...

Page 485: ...light is operational DTC Output signal Malfunction location 1 SAS unit connector poor connection 2 jui SAS unit 3 JUUl Power supply of SAS unit 6 M M Driver side air bag module system 7 JUUUUUUL Passenger side air bag module system 11 J U L Driver side pre tensioner seat belt system 12 Passenger side pre tensioner seat belt system 22 JU U U L Driver side side air bag sensor system Internal circuit...

Page 486: ...ng inspection P erform ing inspection w ith only detection conditions m ay cause inju ry due to operating error o r damage the system W hen perform ing inspection always fo llo w inspection procedure There is no continuity between poor connection detector bar terminals of SAS unit SAS unit connector terminal 2AA is open Vehicles without side air bag Poor connection of any SAS unit connectors POSSI...

Page 487: ...air bag module connector Vehicle with passenger side air bag Disconnect driver and passenger side side air bag module connectors Vehicles with side air bag Remove B pillar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Disconnect all SAS unit connectors Are poor connection detector bars of all SAS unit connectors okay Yes Go to next step No Replace wiring harne...

Page 488: ...ay cause Injury due to operating error or damage the system When performing inspection always follow inspection procedure Voltage detected at SAS unit terminals 2E and 2H is 9 V or less POSSIBLE CAUSE Note DTC 3 is indicated when voltages in both of following wiring harnesses drop simultaneously Wiring harness between fuse block connector JB 01 terminal D and SAS unit connector terminal 2E Wiring ...

Page 489: ...ly injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components See T 56 SERVICE WARNINGS Yes Present malfunction diagnosis Replace SAS unit See T 59 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Remove clock spring See Section T ...

Page 490: ...VIEW FROM TERM INAL SIDE VIEW FROM TERMINAL SIDE MALECONNECTOR SAS UNIT CONNECTOR 2AE 2AB 2Y X 2G 2D 2A 2AF 2AC 2Z 2W 2T 2Q 2N 2K 2H 2E 2B 2AG 2AD 2AA 2X 2U 2R 20 2L 2 1 2F 2C HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE FEMALECONNECTOR Diagnostic procedure STEP INSPECTION ACTION 1 INSPECT SEPARATOR OF CLOCK SPRING Warning Handling air bag system components improperly can accidentally deploy air ...

Page 491: ... Fuel And Thermometer checker or apply 2 2 resistor to clock spring connector terminals A and B Set resistance of SST Fuel And Thermometer checker to 2 2 Connect negative battery cable Turn ignition switch to ON position Is DTC 6 indicated Yes Go to next step No Replace clock spring See Section T 5 INSPECT WIRING HARNESS BETWEEN CLOCK SPRING AND SAS unit Turn ignition switch to LOCK position Disco...

Page 492: ...power supply and open circuit 2D and A 2G and B Are wiring harnesses okay Yes Replace driver side air bag module See Section T No Replace wiring harnesses DTC 7 DTC 7 Passenger side air bag module system DETECTION CONDITION Warning Detection conditions are for understanding DTC outline before performing inspection Performing inspection with only detection conditions may cause Injury due to operati...

Page 493: ... bag system components See T 56 SERVICE WARNINGS Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Remove glove compartment Disconnect passenger side air bag module connector Is separator of passenger side air bag module connector okay Consists of two parts of female connector that separate short bar from terminal when connected to male connect...

Page 494: ...passenger side air bag module See Section T No Replace wiring harnesses 5 VERIFY THAT TERMINAL 2AC OF SAS UNIT CONNECTOR IS GROUNED Warning Handling air bag system components improperly can accidentally deploy air bag modules and pre tensioner seat belts which may seriously injure you Read AIR BAG SYSTEM SER VICE WARNINGS before handling air bag system components See T 56 SERVICE WARNINGS Yes Pres...

Page 495: ...ure STEP INSPECTION ACTION 1 INSPECT OF DRIVER SIDE PRE TENSIONER SEAT BELT CONNECTOR Warning Handling air bag system components Improperly can accidentally deploy air bag modules and pre tensioner seat belts which may seriously injure you Read AIR BAG SYSTEM Yes Replace wiring harness SERVICE WARNINGS before handling air bag system components See T 90 SERVICE WARNINGS Turn ignition switch to LOCK...

Page 496: ...ay Yes Present malfunction diagnosis Replace SAS unit See T 59 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Replace passenger side pre tensioner seat belt See Section S No Replace wiring harness DTC 12 DTC12 Passenger side pre tensioner seat belt system DETECTION CONDITION Warning Detection conditions are for understanding DTC outline before performing inspection Performing inspection ...

Page 497: ...rim Disconnect passenger side pre tensioner seat belt connector Is there cracking or chipping in passenger side pre tensioner seat belt connector Yes Replace wiring harness No Present malfunction diagnosis Go to next step Past malfunction diagnosis Go to Step 3 2 VERIFY WHETHER MALFUNCTION IS IN PASSENGER SIDE PRE TENSIONER SEAT BELT OR OTHER PARTS Connect leads of SST Fuel And Thermometer checker...

Page 498: ... bag Remove passenger side B pillar lower trim Disconnect passenger side pre tensioner seat belt connector Remove side walls Disconnect all SAS unit connectors Inspect wiring harness between terminal 31 of SAS unit connector and terminal A of passenger side pre tensioner seat belt connector and between terminal 3K of SAS unit connector and terminal B of passenger side pre tensioner seat belt conne...

Page 499: ...thout side air bag SAS unit connector terminal 2AA is open POSSIBLE CAUSE Vehicle with side air bag Driver side side air bag sensor malfunction Open or short circuit in wiring harness between driver side side air bag sensor and SAS unit SAS unit malfunction Vehicle without side air bag Malfunction of connector between SAS unit and ground Open or short circuit in wiring harness between SAS unit and...

Page 500: ... belt connectors Remove side walls Disconnect all SAS unit connectors Disconnect driver side side air bag sensor connector Inspect following wiring harness between SAS unit and driver side side air bag sensor terminals harness side for short to ground short to power supply and open circuit 1B and A 1D and B 1F and C 1E and D Are wiring harnesses okay No Replace wiring harnesses 3 INSPECT GROUND CI...

Page 501: ...y seriously injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components See T 56 SERVICE WARNINGS Turn ignition switch to LOCK position Disconnect negative battery cable and wait for more than 1 minute Remove clock spring See Section T Remove glove compartment Disconnect passenger side air bag module connector Disconnect driver and passenger side pre tensioner seat be...

Page 502: ...ir bag SAS unit connector terminal 2AA is open POSSIBLE CAUSE Vehicle with side air bag Driver side side air bag sensor malfunction Open or short circuit in wiring harness between driver side side air bag sensor and SAS unit SAS unit malfunction Vehicle without side air bag Malfunction of connector between SAS unit and ground Open or short circuit in wiring harness between SAS unit and ground SAS ...

Page 503: ...for short to ground short to power supply and open circuit 1B and A 1D and B 1F and C 1E and D Are wiring harnesses okay Yes Present malfunction diagnosis Go to next step Past malfunction diagnosis Replace driver side side air bag sensor See T 58 SIDE AIR BAG SENSOR REMOVAL INSTALLATION No Replace wiring harnesses 3 INSPECT DRIVER SIDE SIDE AIR BAGSENSOR Measure resistance between driver side side...

Page 504: ... fol lowing Short to power supply Open circuit Is wiring harness okay Yes Present malfunction diagnosis Replace SAS unit See T 59 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed No Replace wiring harness DTC26 DTC26 Driver side side air bag module system DETECTION CONDITION Warning Detection conditions are for understanding DTC outline before performing inspectio...

Page 505: ...DE MALECONNECTOR SHORT BAH FEMALECONNECTOR SEPARATOR Diagnostic procedure STEP INSPECTION ACTION 1 Is vehicle equipped with side air bag Yes Go to next step No Go to Step 5 2 INSPECT SEPARATOR OF DRIVER SIDE SIDE AIR BAG MODULE CONNECTOR Warning Handling air bag system components improperly can accidentally deploy air bag modules and pre tensioner seat belts which may seriously injure you Read AIR...

Page 506: ... Disconnect negative battery cable and wait for more than 1 minute Remove clock spring See Section T Remove glove compartment Disconnect passenger side air bag module connector Disconnect passenger side side air bag module connector Remove B pillar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Remove side walls Disconnect all SAS unit connectors Inspect follow...

Page 507: ...owing Short to power supply Open circuit Is wiring harness okay Yes Present malfunction diagnosis Replace SAS unit See T 59 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed No Replace wiring harness DTC32 DTC32 Passenger side side air bag sensor system Internal circuit abnormal DETECTION CONDITION Warning Detection conditions are for understanding DTC outline befo...

Page 508: ...unit and ground Open or short circuit in wiring harness between SAS unit and ground SAS unit malfunction SAS UNIT CONNECTOR PASSENGEH SIDE SIDE AIR ___________ _ _ _ _ _ _ BAG SENSOR CONNECTOR 2AE 2AB 2Y x 2G 2D 2A 2AF 2AC 2Z 2W 2T 2 0 2N 2K 2H 2E 2B 2AG 2AD 2AA 2X 2 U 2R 2 0 2L 21 2F 2C I x P 1K 11 1G 1 E O 1L 1J 1 H 1 F 1D 1B A C B D HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE HARNESS SIDE CON...

Page 509: ... connectors Remove side walls Disconnect all SAS unit connectors Disconnect passenger side side air bag sensor connector Inspect following wiring harness between SAS unit and passenger side side air bag sensor terminals harness side for short to ground short to power supply and open circuit 1L and A 1J and B 1H and C 1G and D Are wiring harnesses okay No Replace wiring harnesses 3 INSPECT GROUND C...

Page 510: ...N Past malfunction diagnosis Troubleshooting completed Remove glove compartment Remove B pillar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Disconnect passenger side air bag module connector Remove side walls Disconnect all SAS unit connectors Inspect wiring harness between SAS unit connector terminal 2AA and ground for following Short to power supply Open c...

Page 511: ...ground SAS unit malfunction SAS UNIT CONNECTOR Í 1 1I X I f 1K 11 1G 1E 1C 1 A 1 L 1J 1 H 1 F 1 D 1 B 2AE 2AB 2Y 2G 2D 2A 2AF 2AC 2Z 2W 2T 2Q 2N 2K 2H 2E 2B 2AG 2AD 2AA 2X 2U 2R 2 0 2L 2 I 2F 2C HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE PASSENGER SIDE SIDE AIR BAG SENSOR PASSENGER SIDE SIDE AIR BAG SENSOR CONNECTOR C A D B J u V COMPONENT SIDE CONNECTOR VIEW FROM TERMINAL SIDE HARNESS SIDE CON...

Page 512: ...t driver and passenger side pre tensioner seat belt connectors Remove side walls Disconnect all SAS unit connectors Disconnect passenger side side air bag sensor connector Inspect following wiring harness between SAS unit and passenger side side air bag sensor terminals harness side for short to ground short to power supply and open circuit 1L and A 1J and B 1H and C 1G and D Are wiring harnesses ...

Page 513: ...mproperly can accidentally deploy air bag modules and pre tensioner seat belts which may seriously injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components See T 56 SERVICE WARNINGS Yes Present malfunction diagnosis Replace SAS unit See T 59 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed Turn ignition switch to LOCK position Disc...

Page 514: ...nnector terminal 2AA is open POSSIBLE CAUSE Vehicle with side air bag Passenger side side air bag module malfunction Malfunction of connector between passenger side side air bag module and SAS unit Open or short circuit in wiring harness between passenger side side air bag module and SAS unit SAS unit malfunction Vehicle without side air bag Malfunction of connector between SAS unit and ground Ope...

Page 515: ...de side air bag module connector terminals A and B Set resistance of SST Fuel And Thermometer checker to 2 i l Connect negative battery cable Turn ignition switch to ON position Is DTC 37 indicated Yes Go to next step No Replace passenger side side air bag module See Section T 4 INSPECT WIRING HARNESS BETWEEN PASSENGER SIDE SIDE AIR BAG MODULE AND SAS UNIT Turn ignition switch to LOCK position Dis...

Page 516: ...ort to power supply Open circuit Is wiring harness okay Yes Present malfunction diagnosis Replace SAS unit See T 59 SAS UNIT REMOVAL INSTALLATION Past malfunction diagnosis Troubleshooting completed No Replace wiring harness DTC44 DTC44 Short to ground In wiring harness between SAS unit and occupancy sensor DETECTION CONDITION Warning Detection conditions are for understanding DTC outline before p...

Page 517: ...nnect passenger side air bag module connector Disconnect driver and passenger side side air bag module connectors Vehicle with side air bag Remove B pillar lower trim Disconnect driver and passenger side pre tensioner seat belt connector Remove side walls Disconnect all SAS unit connectors Disconnect occupancy sensor connector Inspect wiring harness between terminal B of occupancy sensor connector...

Page 518: ...sor Open circuit in wiring harness between occupancy sensor and ground Open circuit in wiring harness between METER 7 5 A fuse and occupancy sensor SAS unit malfunction OCCUPANCY SENSOR CONNECTOR pg SAS UNIT CONNECTOR HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE n f 3K 31 3G 3E 3C 3A 3L 3J 3H 3F 3D 3B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE Diagnostic procedure STEP INSPECTION ACTION 1 Note...

Page 519: ...ng harness 3 INSPECT FOR CONTINUITY BETWEEN OCCUPANCY SENSOR AND GROUND Yes Go to next step Is there continuity between terminal C of occupancy sensor connector and ground No Replace wiring harness 4 INSPECT FOR CONTINUITY BETWEEN METER 10 A FUSE AND OCCUPANCY SENSOR Connect negative battery cable Measure voltage at terminal A of occupancy sensor connector Is voltage more than 9 V Yes Present malf...

Page 520: ...P 2N 2L 2J 2H 2F 2D 2B n n 2 0 2M 2K 21 2G 2E 2C 2A 2P 2N 2L 2J 2H 2F 2D 2B n f 3K 3 1 3G 3E 3C 3A 3L 3J 3H 3F 3D 3B HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE HARNESS SIDE CONNECTOR VIEW FROM HARNESS SIDE HARNESS SIDE CONNECTOR VIEW FROM TERMINAL SIDE Diagnostic procedure STEP INSPECTION ACTION 1 Note If occupancy sensor connector 3 terminals is located on bottom of passenger s seat vehicle ha...

Page 521: ...ect negative battery cable Turn ignition switch to ON position Measure voltage at 3G of SAS unit connector Is voltage more than 9V No Go to next step 5 INSPECT WIRING HARNESS BETWEEN INSTRUMENT CLUSTER AND SAS UNIT Turn ignition switch to LOCK position Disconnect negative battery cable Remove instrument cluster Inspect wiring harness between terminal 2F of instrument cluster connector and terminal...

Page 522: ... See Section T Remove glove compartment Disconnect passenger side air bag module connector Disconnect driver and passenger side side air bag module connectors Vehicle with side air bag Remove B plllar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Remove side walls Disconnect all SAS unit connectors Inspect wiring harness between terminal 2F of instrument clust...

Page 523: ...bag system warning light circuit_______________________________________ POSSIBLE CAUSE Air bag system warning light bulb malfunction METER 7 5 A fuse malfunction Instrument cluster malfunction Malfunction of connectors between instrument cluster and SAS unit Open or short circuit in wiring harness between METER 10 A fuse and instrument cluster Open or short circuit in wiring harness between instru...

Page 524: ...Go to next step No Repair wiring harness 6 INSPECT WIRING HARNESS BETWEEN INSTRUMENT CLUSTER AND SAS UNIT Warning Handling air bag system components improperly can accidentally deploy air bag modules and pre tensioner seat belts which may seriously injure you Read AIR BAG SYSTEM SERVICE WARNINGS before handling air bag system components See T 56 SERVICE WARNINGS Turn ignition switch to LOCK positi...

Page 525: ...RING HARNESS BETWEEN DLC AND SAS UNIT Inspect wiring harness between DLC terminal FAB and SAS unit connector terminal 2W for following Short to ground Short to power supply Is wiring harness okay Yes Troubleshooting completed No Replace wiring harness T 103 ...

Page 526: ...circuit open circuit or short to power supply POSSIBLE CAUSE SAS unit malfunction Instrument cluster print plate malfunction Air bag system warning light bulb malfunction Poor contact in instrument cluster connector 18 pin Open or short circuit in wiring harness between instrument cluster and SAS unit Simultaneous poor contact at terminals 2T and 2Q of SAS unit connector Simultaneous poor contact ...

Page 527: ...nnectors With side air bag Remove B pillar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Remove left side side wall Disconnect all SAS unit connectors Disconnect instrument cluster connector Is there continuity between terminal 2W of SAS unit connector and terminal 1R of instrument cluster connector 18 pin Yes Go to next step No Replace wiring harness then go ...

Page 528: ...S ILLUMINATED ALL THE TIME 2 Air bag system warning light is illuminated all the time DETECTION CONDITION Malfunction in air bag system warning circuit short to ground POSSIBLE CAUSE SAS unit malfunction Instrument cluster print plate malfunction Malfunction of short bar between terminals 2W and 2T of SAS unit connector No connection in SAS unit connector Short circuit in wiring harness between in...

Page 529: ...INSTALLATION 4 INSPECT WIRING HARNESS BETWEEN SAS UNIT AND INSTRUMENT CLUSTER FOR SHORT TO GROUND Remove instrument cluster Caution Be sure not to cause damage to short bar when inserting insulation If short bar is damaged you may not be able to properly inspect SAS unit connectors Insert insulating material between terminals 2W and 2T of SAS unit connector so short bar cannot function Is there co...

Page 530: ...light does not dim DETECTION CONDITION Malfunction in TNS relay circuit open circuit Child restraint seat s built In resonator is attached to passengers seat POSSIBLE CAUSE SAS unit malfunction TNS signal circuit malfunction Terminal 3F of SAS unit connector malfunction Poor connection at terminal 3F of SAS unit connector Open circuit in wiring harness between TNS relay and SAS unit Diagnostic pro...

Page 531: ...ctor With passenger side air bag Disconnect driver and passenger side side air bag module connectors With side air bag Remove B pillar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Remove left side side wall Disconnect all SAS unit connectors Is terminal 3F of SAS unit damaged No Go to next step 3 INSPECT SAS UNIT CONNECTOR TERMINAL 3F Yes Replace wiring harne...

Page 532: ...ME 4 Passenger side air bag cut off Indicator light Is illuminated all the time DETECTION CONDITION Malfunction in TNS relay circuit short to B Child restraint seat s built in resonator is attached to passengers seat POSSIBLE CAUSE SAS unit malfunction TNS signal circuit malfunction Short circuit in wiring harness between TNS relay and SAS unit Diagnostic procedure When performing an asterisked tr...

Page 533: ...e connector With passenger side air bag Disconnect driver and passenger side side air bag module connectors With side air bag Remove B pillar lower trims Disconnect driver and passenger side pre tensioner seat belt connectors Remove left side side wall Disconnect all SAS unit connectors Connect negative battery cable Turn ignition switch to ON position Measure voltage at terminal 3F of SAS unit co...

Page 534: ... bag module connector Yes Complete troubleshooting then explain repairs to cus tomer Connect clock spring connector Connect TNS relay connector Connect negative battery cable Attach child restraint seat built in resonator to passenger side seat Turn headlight switch off Turn ignition switch to ON position Does passenger side air bag cut off indicator light illuminate for approximately 6 seconds an...

Page 535: ...CE INFORMATION U 10 CONTROL SYSTEM U 11 STRUCTURAL VIEW U 11 BLOWER RELAY INSPECTION U 12 CLIMATE CONTROL UNIT DISASSEMBLY ASSEMBLY U 12 CLIMATE CONTROL UNIT INSPECTION U 14 TROUBLESHOOTING U 17 FOREWORD U 17 TROUBLESHOOTING INDEX U 17 NO 1 WINDSHIELD FOGGED U 18 NO 2 NO AIR CONDITIONING SYSTEM FUNCTIONS OPERATE U 20 NO 3 INDICATIONS OF CLIMATE CONTROL UNIT INDICATOR LIGHT ARE INCORRECT U 21 NO 4 ...

Page 536: ... is designed to automatically turn the air intake mode to FRESH when the airflow mode selector dial is turned to DEFROSTER position Manual air conditioner with defroster control To improve the effectiveness of windshield defrosting a part of the full auto air conditioner control systems airflow volume control and the airflow mode control have been changed Full auto air conditioner Improved comfort...

Page 537: ...Vane rotary H12A0 Discharge capacity ml cc fl oz 120 120 4 06 Max allowable speed rpm 6 400 Lube oil Type ATMOS GU10 Sealed volume ml cc fl oz 150 150 5 07 Magnetic clutch clearance mm in 0 4 0 6 0 016 0 023 Condenser Type Multiflow Radiated heat kW kcal h 6 163 5300 condenser 32 lines 4 826 4150 condenser 26 lines Receiver drier Capacity ml cc fl oz 310 310 10 5 Desiccant Synthetic zeolite Expans...

Page 538: ...as been added The air filter cannot be reused and must be replaced periodically Compared to previous air filters the new air filter is gray even when new Be careful not to mistake the new filter for a dirty filter due to its gray color 1 Profile of air filter 2 Staple fiber 3 Deodorant 4 Air filter U 4 ...

Page 539: ...ction are available with the manual air conditioner SEMI LOGIC TYPE FULL LOGIC TYPE 1 Temperature control dial 2 Fan control switch 3 Airflow mode selector dial 4 Air intake selector switch 5 A C switch 6 Rear window defroster switch 7 Temperature control lever 8 Fan control lever 9 Airflow mode selector switch U 5 ...

Page 540: ...s air intake mode and A C ON OFF are controlled based on the input signal of each switch The transition of air intake mode and A C ON OFF when the defroster control operates is as follows 1 Airflow mode is DEFROSTER 2 Airflow mode is except DEFROSTER 3 Air intake mode is REC 4 Air intake mode is FRESH 5 A C compressor is ON 6 A C compressor is OFF 7 DEFROSTER switch is pushed 8 Except defroster sw...

Page 541: ...correction Mild start correction MAX HOT and MAX COLD correction Windshield mist prevention correction Airflow volume regulation Start compensation correction Defroster correction Fail safe function Airflow volume manual control Defroster correction Fail safe function Airflow mode control Airflow mode automatic control Coolant temperature correction Ambient temperature correction Fail safe functio...

Page 542: ...or control condition 8 Signals 9 Climate control unit 10 Output 11 Feedback 12 Air mix actuator 13 Operation 14 Air mix door 15 Airflow temperature changes 16 Coolant temperature C o rre c tio n C o o la n t te m p e ra tu re c o rre c tio n R F T u rb o o n ly There are cases where the engine coolant temperature is lowered when continuously idling in extremely low outside temperatures To prevent ...

Page 543: ... unit 11 Output 12 Feedback 13 Airflow mode actuator 14 Operation 15 Airflow mode doors 16 Airflow mode changes 17 Ambient temperature C o rre c tio n A m b ie n t te m p e ra tu re c o rre c tio n To improve windshield and front door glasses from fogging airflow mode is fixed at HEAT DEF when the ambient temperature is low However ambient temperature correction does not operate when the temperatu...

Page 544: ...Workshop Manual Supplement 1603 10 97K and Mazda 626 626 Station Wagon Workshop Manual Supplement 1614 10 98D B lo w e r re la y Inspection procedure has been modified C lim a te c o n tro l u n it Disassembly assembly procedure has been modified Inspection procedure has been modified S e m i a n d fu ll lo g ic ty p e m a n u a l a ir c o n d itio n e r s y s te m s Troubleshooting has been modif...

Page 545: ... r FULL LOGIC TYPE 8 A C relay and condenser fan relay 9 Blower relay 10 Refrigerant pressure switch 11 Thermal protector 12 Climate control unit 13 A C amplifier 1 Air intake actuator 2 Air mix actuator 3 Airflow mode actuator 4 Blower motor 5 Condenser fan 6 Resistor 7 Magnetic clutch U 11 ...

Page 546: ...mble in the order indicated in the table 2 Assemble in the reverse order of disassembly 1 Air mix wire See U 12 Wire disassembly note 2 Airflow mode wire See U 12 Wire disassembly note 3 Dial See U 12 Dial assembly note 4 Pinion gear 5 Steel ball 6 Spring 7 Panel 8 A C switch 9 Rear window defroster switch 10 Illumination bulb 11 Nut 12 Fan switch 13 Cover 14 CPU 15 Air intake selector switch 16 B...

Page 547: ...to the pinion gears in the straight up and straight down positions as shown 1 2 Full loglc Type 1 Disassemble in the order indicated in the table 2 Assemble in the reverse order of disassembly 1 Knob 2 Fan switch 3 Illumination bulb U 13 ...

Page 548: ...Power supply HEATER 40 A fuse Under any condition B Inspect related harness Inspect HEATER 40 A fuse B GND GND Under any condition inspect for continuity to ground Yes C Panel light control Panel light control SW Inspect terminal C of panel light control switch Inspect related harness Inspect panel light control SW D TNS TNS relay Headlight switch at first or second position B Inspect related harn...

Page 549: ...spect A C 15 A fuse Ignition switch at LOCK position 0 1B Motor drive Air mix actuator Moving to HOT 0 Inspect related harness Inspect air mix actuator Moving to COLD 10 5 1D Motor drive Airflow mode actuator Moving to DEFROSTER 10 5 Inspect related harness Inspect airflow mode actuator Moving to VENT 0 1G Power supply ROOM 10 A fuse Under any condition B Inspect related harness Inspect ROOM 10 A ...

Page 550: ... Instrument cluster Rear window defroster is on 0 Inspect related harness Inspect instrument cluster I Rear window defroster is off 5 2J Potentiomet er input Air mix actuator Set temperature is at MAX COLD 0 75 Inspect related harness Inspect air mix actuator Inspect terminal voltage climate control unit 2N Set temperature is at MAX HOT 4 75 2M Motor drive Air intake actuator Moving to RECIRCULATE...

Page 551: ... on climate control unit do not illuminate or their indications are incorrect U 21 NO 3 INDICATIONS OF CLIMATE CONTROL UNIT INDICATOR LIGHT ARE INCORRECT 4 Insufficient air or no air blown from vents Problem with each vent and or duct U 23 NO 4 INSUFFICIENT AIR OR NO AIR BLOWN FROM VENTS 5 Amount of air blown from vents does not change Malfunction in blower system U 24 NO 5 AMOUNT OF AIR BLOWN FRO...

Page 552: ...ply grease then go to Step 13 3 INSPECT WIRING HARNESS BETWEEN FUSE BLOCK AND CLIMATE CONTROL UNIT FOR CONTINUITY Turn ignition switch to ON position Disconnect climate control unit connector 7 pin Test voltage at climate control unit connector 7 pin terminal E IG2 signal Is voltage approximately 12 V Yes Go to next step No Repair wiring harness between fuse block and climate control unit then go ...

Page 553: ...step 10 INSPECT WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR FOR SHORT TO B Turn ignition switch to ON position Test voltage at following climate control unit connector 7 pin terminals Terminal G FRESH signal Terminal F RECIRCULATE signal Is voltage approximately 12 V Yes Repair wiring harness between climate control unit and air intake actuator then go to Step 13 No Replace...

Page 554: ...BETWEEN CLIMATE CONTROL UNIT AND GROUND Turn ignition switch to LOCK position Disconnect climate control unit connector 12 pin Is there continuity between climate control unit connector 12 pin terminal 1K GND signal and ground Yes Replace climate control unit then go to Step 5 No Repair wiring harness between climate control unit and ground then go to Step 5 3 INSPECT CLIMATE CONTROL UNIT POWER SU...

Page 555: ...operative Yes Go to Step 1 of troubleshooting index NO 2 No Go to next step 3 CHECK TO SEE WHETHER MALFUNCTION IS IN REAR WINDOW DEFROSTER SWITCH LED SYSTEM OR ELSEWHERE Does LED in rear window defroster switch illuminate when switch is turned on Yes Go to Step 11 No Go to next step 4 CHECK FOR DTC 17 IN INSTRUMENT CLUSTER Inspect rear window defroster switch LED using instrument cluster input out...

Page 556: ...ctor 16 pin Is there continuity between climate control unit connector 16 pin terminal 21 and instrument cluster connector 20 pin terminal 3N Yes Go to next step No Repair wiring harness between climate control unit and instrument cluster then go to Step 12 10 CHECK TO SEE WHETHER MALFUNCTION SHORT TO B IS IN CLIMATE CONTROL UNIT OR WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND INSTRUMENT CLUSTE...

Page 557: ...ing harnesses Are they okay Yes Go to next step No Repair or replace malfunctioning part then go to Step 10 5 VERIFY THAT DUCT IN DASHBOARD IS INSTALLED Is duct In dashboard properly installed Yes Check duct for clogging deformity and air leakage then go to Step 10 No Install duct securely in proper position then go to Step 10 6 CHECK TO SEE WHETHER MALFUNCTION IS IN HEAT MODE OR DEFROSTER MODE Do...

Page 558: ...R AFTER REPAIR Does air blow out Yes Troubleshooting completed Explain repairs to customer No Recheck malfunction symptoms then repeat from Step 1 if malfunction recurs NO 6 AIRFLOW MODE DOES NOT CHANGE 6 Airflow mode does not change DESCRIPTION Airflow mode does not change when operating airflow mode POSSIBLE CAUSE Airflow mode actuator 5V signal system malfunction Steps 2 6 9 Climate control uni...

Page 559: ...V signal Yes Inspect airflow mode actuator then go to Step 18 No Go to next step 6 CHECK TO SEE WHETHER MALFUNCTION SHORT TO GROUND IS IN CLIMATE CONTROL UNIT OR WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND AIRFLOW MODE ACTUATOR Disconnect climate control unit connector 16 pin Is there continuity between climate control unit connector 16 pin terminal 2N 5 V signal and ground Yes Repair wiring h...

Page 560: ...al and ground Yes Repair wiring harness between climate control unit and airflow mode actuator then go to Step 18 No Go to next step 12 CHECK TO SEE WHETHER MALFUNCTION SHORT TO B IS IN WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND AIRFLOW MODE ACTUATOR OR ELSEWHERE Turn ignition switch to ON position Test voltage at climate control unit connector 16 pin terminal 2E potentiometer input signal Is...

Page 561: ...n air intake actuator system Steps 5 6 Malfunction in blower unit air intake door Steps 7 8 Diagnostic procedure When performing an asterisked troubleshooting inspection shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions If there is a problem check to make sure connectors terminals and wiring har...

Page 562: ... cracks or damage then go to next step No Install air intake door securely in proper position then go to next step 9 CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR Does air intake mode change when operating air intake selector switch Yes Troubleshooting completed Explain repairs to customer No Recheck malfunction symptoms then repeat from Step 1 if malfunction recurs NO 8 NO TEMPERATU...

Page 563: ...al 2N 5 V signal Yes Inspect airflow mode actuator then go to Step 19 No Go to next step 7 CHECK TO SEE WHETHER MALFUNCTION SHORT TO GROUND IS IN CLIMATE CONTROL UNIT OR WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND AIR MIX ACTUATOR Disconnect climate control unit connector 16 pin Is there continuity between climate control unit connector 16 pin terminal 2N 5 V signal and ground Yes Repair wirin...

Page 564: ...t signal and ground Yes Repair wiring harness between climate control unit and air mix actuator then go to Step 19 No Go to next step 13 CHECK TO SEE WHETHER MALFUNCTION SHORT TO B IS IN WIRING HARNESS BETWEEN CLIMATE CONTROL UNIT AND AIR MIX ACTUATOR OR ELSEWHERE Turn ignition switch to ON position Test voltage at climate control unit connector 16 pin terminal 2J potentiometer input signal Is vol...

Page 565: ...erant lines Steps 10 13 A C compressor system malfunction insufficient compressor oil Step 16 Too much compressor oil expansion valve heat sensing tube installed incorrectly malfunction in expansion valve valve opens too much malfunction in heater unit air mix link system Steps 18 20 Diagnostic procedure STEP INSPECTION ACTION 1 INSPECT DRIVE BELT Inspect drive belt Is it okay Yes Go to next step ...

Page 566: ...inspection Are piping connections free of gas leakage Are piping installation points on condenser free of gas leakage Are piping installation points on receiver drier free of gas leakage Are piping installation points on A C compressor free of gas leakage Are piping installation points on cooling unit free of gas leakage Perform gas leak inspection using gas leak tester Are above items okay Yes Go...

Page 567: ...sufficient compressor oil No Replace A C compressor then go to Step 21 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 20 No Go to next step 18 VERIFY THAT AIR MIX ACTUATOR IS INSTALLED SECURELY AND PROPERLY Are heater unit air mix links air mix cranks and air mix rods securely and p...

Page 568: ...ic clutch thermal protector and or A C relay A C control signal system Steps 22 24 Diagnostic procedure When performing an asterisked troubleshooting inspection shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions If there is a problem check to make sure connectors terminals and wiring harness are ...

Page 569: ...witch is off and 0 V when it is on Yes Go to Step 16 No Reconnect refrigerant pressure switch then go to next step 10 CHECK TO SEE WHETHER MALFUNCTION LACK OF CONTINUITY IS IN A C AMPLIFIER AND WIRING HARNESS BETWEEN FUSE BLOCK AND A C AMPLIFIER OR ELSEWHERE Turn ignition switch to LOCK position Disconnect A C amplifier Start engine Turn both A C switch and fan switch on When A C amplifier connect...

Page 570: ...HARNESS BETWEEN PCM AND REFRIGERANT PRESSURE SWITCH OR ELSEWHERE Turn ignition switch to ON position Test voltage at refrigerant pressure switch connector terminal A A C signal on wiring harness side Is voltage approximately 12 V Yes Go to Step 18 No Go to next step 17 CHECK TO SEE WHETHER MALFUNCTION LACK OF CONTINUITY IS IN PCM OR WIRING HARNESS BETWEEN PCM AND REFRIGERANT PRESSURE SWITCH Test v...

Page 571: ...o ON position Test voltage at A C relay connector terminal C A C control signal Is voltage approximately 12 V Yes Go to next step No Repair wiring harness between fuse block and A C relay then go to Step 25 24 CHECK TO SEE WHETHER MALFUNCTION LACK OF CONTINUITY IS IN MAGNETIC CLUTCH AND THERMAL PROTECTOR OR WIRING HARNESS BETWEEN A C RELAY AND MAGNETIC CLUTCH Test voltage at magnetic clutch connec...

Page 572: ...TECHNICAL DATA TECHNICAL DATA TD 2 AUTOMATIC TRANSAXLE TD 2 FRONT AND REAR AXLES TD 2 SUSPENSION TD 3 BODY ELECTRICAL SYSTEM TD 3 TD 1 ...

Page 573: ...ture 40 160 C 40 320 F 250 600 Solenoid valve O Shift solenoid A 1 0 4 2 Shift solenoid B 1 0 4 2 Shift solenoid C 1 0 4 2 Shift solenoid D 10 9 26 2 Shift solenoid E 10 9 26 2 Pressure control solenoid 2 4 7 3 Automatic transaxle fluid ATF Type ATF M 1II or equivalent e g Dexron n Capacity L US qt Imp qt 7 2 7 6 6 3 FRONT AND REAR AXLES Item Engine FP FS Sedan Hatcback FS Wagon RF Turbo Transaxle...

Page 574: ...light Interior type 21 1 Spoiler type 4 1 Interior light L H D 8 1 R H D 10 1 Map light 5 2 Cargo compartment light 5HB 5 1 Station wagon 8 1 Interior light bulb capacity Trunk compartment light 5 1 W Glove compartment light 1 2 1 Ignition key illumination 1 6 1 Front ashtray illumination 1 4 1 Instrument cluster illumination 3 4 2 1 4 2 Air bag system warning light 1 4 1 Oil pressure warning ligh...

Page 575: ...SPECIAL TOOLS SPECIAL TOOLS ST 2 FUEL AND EMISSION CONTROL SYSTEMS ST 2 AUTOMATIC TRANSAXLE ST 2 FRONT AND REAR AXLES ST 2 BRAKING SYSTEM ST 3 BODY ELECTRICAL SYSTEM ST 3 ST 1 ...

Page 576: ... 0378 400B Oil pressure gauge set 49 B019 901A Oil pressure gauge set 49 H019 002 Adapter 49 G017 5A0 Engine support 49 T028 3A0 Ball joint puller set 49 G030 455 Diff side gear holder 49 E011 1AO Ring gear brake set 49 G030 795 Oil seal installer 49 T088 0A4 49 T088 0A5 NGS tester set Program card SST No for Program card varies with language 49 T088 030F English French 49 T088 031F English German...

Page 577: ...r set SST No for Program card varies with 49 T088 037C English Danish language 49 T088 038C English Norwegian Program card 49 T088 030F English French 49 T088 039C English Czech 49 T088 031F English German 49 T088 040A English Finnish 49 7088 032F English Dutch 49 T088 041C English Greek 49 T088 033F English Swedish 49 T088 042C English Hungarian 49 T088 034D English Spanish 49 T088 043C nglish Po...

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